Part 2
EngineAssembly (Steps 31-60)
31. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using a vise.
32. Install a retaining clip on the tensioner to hold the plunger in during installation.
All engines
33. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
34. Using the special tool, position the crankshaft.
^ Remove the special tool after crankshaft positioning.
35. Install the crankshaft sprocket, making sure the flange faces forward.
36. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the 2 LH bolts to 10 Nm (89 inch lbs.).
3 Position the RH timing chain guide.
4 Install and tighten the 2 RH bolts to 10 Nm (89 inch lbs.).
37. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
39. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
40. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Engines with ratcheting timing chain tensioners
41. Remove the retaining clip from the LH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
42. Remove the retaining clip from the LH timing chain tensioner.
All engines
43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
44. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Engines with ratcheting timing chain tensioners
46. Remove the retaining clip from the RH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
47. Remove the retaining clip from the RH timing chain tensioner.
All engines
48. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
49. Rotate and camshaft until the lobe is in the up position.
50. Install the special tool between the valve spring coil to prevent valve stem seal damage.
51. NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Install the 16 camshaft roller followers.
1 Install the special tool.
2 Compress the valve spring.
3 Install the 16 camshaft roller followers in their original locations.
52. Remove the special tool.
53. Install all 8 spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).
54. Install the crankshaft sensor ring.
55. NOTE: RH timing chain removed for clarity.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. 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 a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
56. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
57. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).
58. NOTE: RH shown, LH similar.
Install the RH and LH engine mounts and the 6 bolts.
^ Tighten to 70 Nm (52 ft. lbs.).
59. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
60. Using the special tools, install the front oil seal.