Part 2
Assembly Note Continued50. Tighten the 15 bolts and 2 nuts.
51. Tighten the ladder frame bolts.
52. Tighten the inserts.
53. Install new seals on the two silver bolts and position them in the ladder frame.
54. Position the six remaining bolts.
55. Tighten the ladder frame bolts in two stages.
1) Stage 1: Tighten to 15 Nm (1.5 kgf-m, 11 lb-ft).
2) Stage 2: Tighten to 33 Nm (3.3 kgf-m, 24 lb-ft).
Note:
^ Assemblies that measure out of specification must have the entire assembly procedure repeated.
56. Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.
57. Repair all assemblies that exceed under-flush specification by installing shims on one or both sides of the ladder frame.
58. Install the oil pump screen cover and tube.
59. Install the gasket, and the oil pan. Tighten the bolts.
60. Install the oil filter adapter and tighten.
61. Install the oil filter and tighten.
62. Install the water pump and tighten the bolts.
Note:
^ LH shown, RH similar.
63. Install the cylinder head gasket.
Note:
^ LH shown, RH similar.
64. Install the cylinder head and tighten the bolts in the sequence shown.
Note:
^ LH shown, RH similar.
65. Install the two 8 mm bolts and tighten.
Note:
^ LH shown, RH similar.
66. Tighten the cylinder head bolts in the sequence shown in two stages.
1) Stage 1: Rotate 80 degrees.
2) Stage 2: Rotate an additional 80 degrees.
67. Using the Crankshaft Damper Replacer SST 303-102 (or 49UN-01-0020), install the crankshaft pulley.
Caution:
^ A new bolt must be used each time it is removed.
68. Tighten the bolt in two stages.
1) Stage 1: Tighten to 50 N-m (5.0 kgf-m, 37 lb-ft).
2) Stage 2: Rotate an additional 90 degrees.
Caution:
^ The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
69. Install the RH camshaft bolt.
70. Install the bolt and tighten.
Caution:
^ The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
71. Install the LH front camshaft bolt.
72. Install the bolt and tighten.
73. Turn the crankshaft one revolution clockwise.
Note:
^ The crankshaft holding tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).
74. Install the Crankshaft Holding Tool SST 303-573.
Note:
^ Camshaft timing slots are off-center.
Note:
^ Position the camshaft timing slots below centerline of the camshaft to correctly fit the special tools.
75. Install the Camshaft Holding Tool SST 303-577 and Camshaft Holding Tool Adapter SST 303-576 on the front of the RH cylinder head.
Note:
^ Leave the top two special tool clamp bolts loose.
Note:
^ If cam is not in the correct position, the top of SST 303-576 will not sit flush with the top of SST 303-577. Rotate the cam 1800 to set correctly.
76. Install the RH camshaft chain tensioner, but do not tighten.
77. Tighten the camshaft bolt to 85 Nm (8.5 kgf-m, 63 lb-ft).
78. Tighten RH camshaft tensioner.
79. Remove the special tools from the RH cylinder head.
Note:
^ Camshaft timing slots are off-center.
Note:
^ Position the camshaft timing slots below centerline of the camshaft to correctly fit the special tools.
80. Install the Camshaft Holding Tool SST 303-577 and Camshaft Holding Tool Adapter SST 303-576 on the rear of the LH cylinder head.
Note:
^ Leave the top two special tool clamp bolts loose.
Note:
^ If cam is not in the correct position, the top of SST 303-576 will not sit flush with the top of SST 303-577. Rotate the cam 180° to set correctly.
81. Install the LH camshaft chain tensioner, but do not tighten.
82. Tighten the camshaft bolt to 85 Nm (8.5 kgf-m, 63 lb-ft).
Note:
^ When using a new washer, the camshaft tensioner must be tightened to 44 N-m (4.4 kgf-m, 32 lb-ft).
83. Tighten the LH camshaft tensioner.
84. Remove the special tools from the LH cylinder head.
85. Remove the crankshaft holding tool.
Note:
^ Lubricate the parts with clean engine oil prior to installing.
86. Using the Valve Spring Compressor SST 303-581, install the roller followers in their original position.
87. Install the gasket and the RH exhaust manifold. Tighten the bolts.
88. Install the gasket and the LH exhaust manifold. Tighten the bolts.
Note:
^ Prior to installation, use Metal Surface Cleaner to clean mating surfaces.
89. Install the knock sensor and tighten the bolt.
90. Install the oil level indicator tube.
Note:
^ If the oil level indicator tube is not installed flush with the cylinder block, false readings of the oil level may occur.
91. Make sure the oil level indicator tube is flush with the cylinder block.
92. Install the thermostat housing.
1) Install the housing into the bypass hose.
2) Install the bolts and tighten.
3) Position the bypass hose clamp.
93. Install the fuel injectors.
1) Lubricate the fuel injector O-ring seals with engine oil.
94. Install the gasket and the RH valve cover and tighten the bolts.
95. Install the gasket and the LH valve cover and tighten the bolts.
96. Install the fuel rail and tighten the bolts.
97. Install the lower fuel line bracket and tighten the bolt.
98. Connect the EGR valve-to-the exhaust manifold tube to the exhaust manifold and tighten.
99. Connect the EGR valve-to-exhaust manifold tube to the EGR valve and tighten to 34 N-m (3.4 kgf-m, 25 lb-ft).
100. Install the fuel charging wiring.
Note:
^ LH shown, RH similar.
101. Connect the six fuel injector electrical connectors.
102. Connect the water temperature sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
103. Connect the crankshaft position (CKP) sensor electrical connector.
104. Connect the differential pressure feedback EGR transducer
105. Connect the camshaft position (CMP) sensor electrical connector.
106. Attach the wiring harness retainer and install the heater tube bracket assembly.
107. Install the bolts and tighten.
108. Position the intake manifold close to the installed position.
109. Install the heated PCV fitting.
110. Install the intake manifold and tighten the bolts.
111. Connect and attach the electrical connector.
112. Connect the vacuum hoses.
113. Install the coil and ignition wire. Install the bolt and tighten.
114. Install the bolts and tighten.
Caution:
^ Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.
Note:
^ Apply dielectric compound to the inside of the spark plug boots.
115. Connect the spark plug wires to the spark plugs.
116. Connect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
117. Connect the radio ignition interference capacitor electrical connector.
118. Connect the ignition coil electrical connector.
119. Connect the EGR valve-to-exhaust manifold tube to the EGR valve.
120. Connect the idle air control (IAC) valve electrical connector and connect the EGR valve vacuum hose.
121. Connect the throttle position (TP) sensor electrical connector.
122. Install the generator mounting bracket and tighten the bolts.
1) Install the generator mounting bracket bolts.
2) Install the drive belt tensioner bolt and tighten.
123. Install the accessory bracket and tighten the bolts.
124. Rotate the drive belt tensioner counterclockwise and install the drive belt.