Part 2
EngineAssembly (Steps 28-54)
28. Remove the retaining pin.
29. Install the synchronizer drive gear and the bolt.
^ Tighten to 45 Nm (33 ft. lbs).
30. NOTE: Use Thread Sealant with PTFE on studs No. 4 and 6 and bolt No. 12.
Install the engine front cover studs in their original locations.
^ Tighten the 4 engine front cover studs to 7 Nm (62 inch lbs).
31. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
NOTE: Clean and inspect the mating surfaces.
Using a new gasket, install the engine front cover.
^ Using a new gasket, install the coolant pump.
^ Tighten the fasteners in the sequence shown.
- Tighten capscrew No. 12 to 10 Nm (89 inch lbs).
- Tighten all other fasteners to 28 Nm (21 ft. lbs).
32. NOTE: Lubricate the new crankshaft front seal lips with clean engine oil prior to installation.
Assemble the special tools, then place the crankshaft front seal onto the special tools.
33. Using the special tools, install the crankshaft front seal.
34. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
35. Lubricate the crankshaft pulley sealing surface with clean engine oil.
36. NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil prior to installation.
Using the special tool, install the crankshaft pulley.
37. Install the crankshaft pulley washer and the bolt.
^ Tighten to 160 Nm (118 ft. lbs).
38. CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center TDC of the compression stroke on the No. 1 cylinder.
CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
39. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.
40. Install the camshaft synchronizer retaining bolt.
^ Tighten to 25 Nm (18 ft. lbs).
41. Install the CMP sensor and the 2 bolts.
^ Tighten to 3 Nm (27 inch lbs).
42. NOTE: If the oil pan is not installed within 4 minutes, remove the sealant and reapply.
Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
1 Apply silicone gasket and sealant to the rear main bearing cap.
2 Install the oil pan rear seal.
3 Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surfaces.
43. Install the oil pan and 17 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
44. Install the oil pressure sender.
^ Tighten to 27 Nm (20 ft. lbs).
45. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, install a new oil cooler and tube assembly and bolt.
^ Tighten to 35 Nm (26 ft. lbs).
46. NOTE: Lubricate the new engine oil filter seal with clean engine oil prior to installation.
Install a new engine oil filter.
^ Tighten one half turn after the gasket makes contact with the oil filter housing.
47. NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
Using new gaskets, install the RH and the LH cylinder heads.
48. CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the new bolts. Make sure the bolts are installed in the correct locations.
1 Install the new long bolts.
2 Install the new short bolts.
49. Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten to 40 Nm (30 ft. lbs).
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
50. CAUTION: Each bolt must be loosened and the final tightening carried out prior to working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
Carry out this final tightening process on each bolt in the sequence shown.
^ Long bolts:
- Loosen and back out 3 turns.
- Tighten to 45 Nm (33 ft. lbs).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
^ Short bolts:
- Loosen and back out 3 turns.
- Tighten to 25 Nm (18 ft. lbs).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
51. Install the 3 lower exhaust manifold studs on both cylinder heads.
^ Tighten to 8 Nm (71 inch lbs).
52. NOTE: Lubricate the push rods with clean engine oil prior to installation. If reusing the push rods, make sure to install them in their original locations.
Install the 12 push rods.
53. NOTE: If reusing the rocker arms, make sure to install them in their original locations.
Install the 12 rocker arms.
^ Position the rocker arms and pivots.
^ Hand-start the 12 bolts.
^ Tighten the 12 bolts in 2 stages.
- Stage 1: Tighten to 5 Nm (44 inch lbs).
- Stage 2: Tighten to 32 Nm (24 ft. lbs).
54. NOTE: Install new gaskets in the valve covers.
NOTE: RH shown, LH similar.
Install the valve covers.
1 Position the valve covers.
2 Install the bolts and tighten to 10 Nm (89 inch lbs).
3 Install the stud bolts and tighten to 10 Nm (89 inch lbs).
