Part 2

Engine

Assembly (Steps 41-85)

41. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.

42 Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.






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





44. Install a new head gasket.





45. NOTE:The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE:Lubricate the bolts with clean engine oil prior to installation.

Install new cylinder head bolts. Tighten the bolts in the sequence shown in the following 5 stages:
^ Stage 1: Tighten to 5 Nm (44 lb-inch).
^ Stage 2: Tighten to 15 Nm (11 lb-ft).
^ Stage 3: Tighten to 45 Nm (33 lb-ft).
^ Stage 4: Turn 90 degrees.
^ Stage 5: Turn an additional 90 degrees.





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 the following 3 stages:
^ Stage 1: Tighten 1 turn at a time until tight.
^ Stage 2: Tighten to 7 Nm (62 lb-inch).
^ Stage 3: Tighten to 16 Nm (12 lb-ft).





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 lb-ft).





49. Install the shoulder bolt.
^ Tighten to 10 Nm (89 lb-inch).





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





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 lb-inch).





54. Install the timing chain.





55. Install the RH timing chain guide.





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 lb-inch).





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.
^ Tighten to 72 Nm (53 lb-ft).





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 lb-inch).
^ Tighten the 13-mm bolts to 48 Nm (35 lb-ft).





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

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, install the crankshaft front oil seal.





66. NOTE: Do not install the crankshaft pulley bolt at this time.

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

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





67. CAUTION: Only hand-tighten the 6 mm (0.23 inch) 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 top dead center (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.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 lb-ft).
^ Stage 2: Tighten an additional 90 degrees (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, the engine valve timing must be corrected.





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





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 and the 2 bolts.

^ Do not tighten the bolts at this time.





79. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 Nm (62 lb-inch).





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 lb-inch).