Part 1 of 2

Engine








Special Tool(s)





Material














CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

All vehicles





1. If removed, install the crankshaft key into the keyway on the crankshaft.





2. Install the crankcase cover, a new gasket and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





3. NOTE: LH shown, RH similar. Position the LH and RH cylinder heads and gaskets.

Install new bolts and tighten in the sequence shown in six stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 3: Loosen one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten 90 degrees.
^ Stage 6: Tighten 90 degrees.





4. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
5. Apply clean engine oil to the LH and RH camshaft roller followers.





6. CAUTION: The camshaft roller followers must be installed in their original positions.

NOTE: RH shown, LH similar.

Install the LH and RH camshaft roller followers.
7. Apply clean engine oil to the LH and RH camshafts.





8. Install the LH and RH camshafts.
^ Locate the camshafts as shown.





9. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.

CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.

Lubricate the camshaft journal caps with clean engine oil. Position the LH camshaft caps and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





10. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.

CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.

Position the RH camshaft caps and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





11. NOTE: Clean the sealing surface with metal surface cleaner before installing a new press-in-place gasket.

Install the camshaft oil seal retainer and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





12. NOTE: Lubricate the camshaft oil seal with clean engine oil.

Using the special tools, install a new camshaft oil seal.





13. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 inch) past flush of the end of the camshaft. The service pulley is pressed on flush to the end of the camshaft.

Using the special tool, install a new service coolant pump drive pulley.





14. Remove the crankshaft damper bolt.





15. Install the crankshaft sprockets with the timing marks out.





16. NOTE: LH shown, RH similar.

Position the chain tensioner in a soft-jawed vise.





17. NOTE: LH shown, RH similar.

Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

18. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the timing chain tensioner.





19. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.





20. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count 29 links and mark the link.
3. Continue counting to link 42 and mark the link.





21. Position the LH timing chain and guide and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





22. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.)





23. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.





24. Verify that the RH camshafts are correctly postponed.





25. Install the RH timing chain and chain guide and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





26. Install the RH timing chain tensioner and tensioner arm.
1. Install the tensioner arm.
2. Position the tensioner. 3 Install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
27. Remove the LH and RH timing chain tensioner piston retaining wires.
28. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).





29. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.

Verify the timing with the following steps.
1. There should be 12 chain links between the camshaft timing marks.
2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
3. There should be 30 chain links between the camshaft and the crankshaft timing marks.





30. Remove the crankshaft damper bolt.





31. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).

Install the ignition pulse wheel.
32. Install 3 new gaskets in the front cover.





33. NOTE: Clean and degrease the sealing surfaces with metal surface cleaner before applying gasket and sealant.

NOTE: The front cover must be installed and the bolts tightened within four minutes of sealant application.

Apply a 6 mm (0.24 inch) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.





34. NOTE: Fasteners 1, 8, 13 and 16 are stud bolts.

Position the front cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 25 Nm (18 ft. lbs.).





35. Install the belt tensioner and the bolt.
^ Tighten to 45 Nm (33 ft. lbs.).





36. Install the idler pulley and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





37. Using the special tools, install the crankshaft front oil seal.





38. NOTE: Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealant.

NOTE: The crankshaft damper must be installed and the bolt tightened within four minutes of sealant application.

Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.





39. Using the special tool, install the crankshaft vibration damper.





40. Install the crankshaft vibration damper washer and tighten the bolt in four stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs.).
^ Stage 2: Loosen one full turn (360 degrees).
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten to 90 Nm (66 ft. lbs.).





41. Install the knock sensor (KS) and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





42. Install the oil pressure sender and, if equipped, the block heater.
^ Tighten to 14 Nm (10 ft. lbs.).





43. Position the oil pan baffle. Install the nuts and tighten in two stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten 45 degrees.





44. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.





45. Install the oil pump screen and pickup tube.
1. Position the oil pump screen and pickup tube.
2. Install the bolts.
3. Install the nut and tighten in two stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten 45 degrees.