Part 2

Engine





























Assembly (Steps 38-74)
38. Install the RH cassette and sprocket to the jackshaft.
^ Install, but do not tighten the bolt at this time.





39. Install the RH cassette bolt.
^ Tighten to 19 Nm (14 lb-ft).





40. Using the special tool, hold the crankshaft.





41. Tighten the rear jackshaft bolt in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.





42. Install the rear jackshaft plug.





43. Position the front cover gasket, the front cover and loosely install the bolts.





44. Install the special tool and tighten the front cover bolts.
^ Tighten to 19 Nm (14 lb-ft).





45. NOTE: Lubricate the seal lip with clean engine oil.

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





46. CAUTION: The cylinder block cradle inserts must be loosened completely or damage to the cylinder block cradle or oil leaks can result.

Loosen the cylinder block cradle inserts.





47. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the front cover in 4 places.





48. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the rear main bearing cap as shown.
^ Position the cylinder block cradle gasket.





49. Position the cylinder block cradle and gasket assembly.





50. Install and finger-tighten the 20 bolts and 2 nuts.





51. Install and finger-tighten the Torx(R) bolts.





52. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.

Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.





53. Tighten the 20 bolts and the 2 nuts.
^ Tighten the nuts to 10 Nm (89 lb-in).
^ Tighten the bolts to 14 Nm (10 lb-ft).





54. Tighten the Torx(R) bolts.
^ Tighten to 8 Nm (71 lb-in).





55. Tighten the inserts.
^ Tighten to 3 Nm (27 lb-in).





56. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.





57. Position the 6 remaining bolts.





58. Tighten the cylinder block cradle inner bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 15 Nm (11 lb-ft).
^ Stage 2: Tighten to 34 Nm (25 lb-ft).





59. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.

Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
^ Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.
^ Cradles that exceed the underflush specification may be repaired by installing shims (next step).





60. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.





61. Install the oil pump screen cover and tube and the bolt.
^ Tighten to 10 Nm (89 lb-in).





62. Install the gasket, the oil pan and the bolts.
^ Tighten to 11 Nm (8 lb-ft).





63. Install the oil filter adapter and the bolt.
^ Tighten to 57 Nm (42 lb-ft).





64. Install the coolant pump and the bolts.
^ Tighten to 10 Nm (89 lb-in).





65. NOTE: LH shown, RH similar.

Install the cylinder head gaskets.





66. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).





67. Install the two 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).





68. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Rotate 90 degrees.
^ Stage 2: Rotate an additional 90 degrees.





69. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).





70. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).





71. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Rotate 90 degrees.
^ Stage 2: Rotate an additional 90 degrees.





72. Using the special tool, install the crankshaft pulley.





73. NOTE: A new bolt must be used each time it is removed.

Using the special tool, tighten the bolt in 2 stages.
^ Stage 1: Tighten to 50 Nm (37 lb-ft).
^ Stage 2: Rotate an additional 90 degrees.





74. Install the coolant pump pulley and the bolts.
^ Tighten to 25 Nm (18 lb-ft).