Part 2

46. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight.
^ Stage 2: Tighten to 7 Nm (62 inch lbs.).
^ Stage 3: Tighten to 16 Nm (12 ft. lbs.).





47. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.

Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
^ The crankshaft sprocket flange must be facing away from the engine block.





48. Install the oil pump chain, sprocket and bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





49. Install the oil pump chain guide and the shoulder bolts.
^ Tighten to 10 Nm (89 inch lbs.).





50. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
^ Tighten to 10 Nm (89 inch lbs.).





51. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install the special tool in the slots on the rear of both camshafts.





52. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.





53. Install the LH timing chain guide and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





54. Install the timing chain.





55. Install the RH timing chain guide.

NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.





56. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.





57. Using a small pick, push back and hold the ratchet mechanism.





58. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





59. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





60. Install the timing chain tensioner and the bolts.
^ Remove the paper clip to release the piston.
^ Tighten to 10 Nm (89 inch lbs.).





61. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
^ To install, tighten to 72 Nm (53 ft. lbs.).

62. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.





63. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.

Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the front cover.





64. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
^ Tighten the 8 mm bolts to 10 Nm (89 inch lbs.).
^ Tighten the 13 mm bolts to 48 Nm (35 ft. lbs.).





65. NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, Install a new crankshaft front oil seal.

66. NOTE: Do not reuse the crankshaft damper bolt.

NOTE: Apply clean engine oil on the seal area before installing.





Install the crankshaft pulley and hand-tighten the bolt.





67. CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.





68. CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.

NOTICE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.).
^ Stage 2: Tighten an additional 90° (1/4 turn).





69. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





70. Remove the special tool.





71. Remove the special tool.

72. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.





73. Install the special tool.

74. NOTE: Only turn the engine in the normal direction of rotation.





Turn the crankshaft clockwise until the crankshaft contacts the special tool.





75. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, correct the engine timing.





76. Using the special tool, check the position of the camshafts.
^ If it is not possible to install the special tool, correct the engine timing.



77. Remove the special tool.





78. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor.
^ Do not tighten the bolts at this time.





79. Adjust the CKP sensor alignment Jig and tighten the bolts.
^ Tighten to 7 Nm (62 inch lbs.).





80. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.



81. Remove the special tool.





82. Install the engine plug bolt.
^ Tighten to 20 Nm (15 lb-ft.)

83. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the valve cover gasket surface with metal surface cleaner.





84. Apply silicone gasket and sealant to the locations shown.





85. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).





86. NOTICE: Only use hand tools when removing or installing spark plugs, damage can occur to the cylinder head or spark plug.

Install a new cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 ft. lbs.).
^ Tighten the spark plugs to 12 Nm (9 ft. lbs.).





87. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the coil-on-plugs, bolts and the crankcase vent tube.
^ Tighten to 10 Nm (89 inch lbs.).





88. If equipped, install the block heater.
^ Tighten to 40 Nm (30 ft. lbs.).





89. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator and the KS.
^ Tighten the oil separator bolts to 10 Nm (89 inch lbs.).
^ Tighten the KS to 20 Nm (15 ft. lbs.).





90. Install the coolant hoses.





91. Install the coolant hose.