Part 2
Engine
Special Tool(s)
Material(s)
40. Install the KS (Knock Sensor) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
41. NOTE: Early built coolant tube shown, late build coolant tube similar.
NOTE: Apply clean engine coolant to the O-ring seal prior to installation.
Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.
42. Install a new gasket, the RH (Right Hand) cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.
43. Install the bolt.
- Tighten to 10 Nm (89 lb-in).
44. Install a new gasket, the LH (Left Hand) cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.
45. Install the bolt.
- Tighten to 10 Nm (89 lb-in).
46. NOTE: The valve tappets must be installed in their original positions.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
NOTE: LH (Left Hand) shown, RH (Right Hand) similar.
Install the valve tappets.
47. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).
48. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
49. Install the RH (Right Hand) primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
50. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
51. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH (Right Hand) cylinder head in the neutral position as shown.
52. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
53. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
54. Loosen the 4 camshaft caps bolts.
55. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
56. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size.
57. Remove the 3 bolts and the RH (Right Hand) valve train oil tube.
58. Rotate the RH (Right Hand) camshafts to the TDC (Top Dead Center) position as shown.
59. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position.
Install 303-1248 onto the flats of the RH (Right Hand) camshafts.
60. Compress the RH (Right Hand) secondary timing chain tensioner and install 303-1530 to retain the tensioner in the collapsed position.
61. Assemble the RH (Right Hand) VCT (Variable Camshaft Timing) assembly, the RH (Right Hand) exhaust camshaft sprocket and the RH (Right Hand) secondary timing chain.
1. Align the colored links with the timing marks.
62. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH (Right Hand) secondary timing assembly.
Position the 2 RH (Right Hand) VCT (Variable Camshaft Timing) assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT (Variable Camshaft Timing) assemblies with the dowel pins in the camshafts.
63. Install the 2 new RH (Right Hand) VCT (Variable Camshaft Timing) bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
64. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.
Compress the RH (Right Hand) secondary timing chain tensioner and remove the 303-1530.
1. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
65. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH (Left Hand) cylinder head in the neutral position as shown.
66. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
67. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in).
68. Loosen the 4 camshaft caps bolts.
69. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
70. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size.
71. Remove the 3 bolts and the LH (Left Hand) valve train oil tube.
72. Rotate the LH (Left Hand) camshafts to the TDC (Top Dead Center) position as shown.
73. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position.
Install 303-1248 onto the flats of the LH (Left Hand) camshafts.
74. Compress the LH (Left Hand) secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
75. Assemble the 2 LH (Left Hand) VCT (Variable Camshaft Timing) assemblies and the LH (Left Hand) secondary timing chain.
1. Align the colored links with the timing marks.
76. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH (Left Hand) secondary timing assembly.
Position the 2 LH (Left Hand) VCT (Variable Camshaft Timing) assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT (Variable Camshaft Timing) assemblies with the dowel pins in the camshafts.
77. Install the 2 new LH (Left Hand) VCT (Variable Camshaft Timing) bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
78. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.
Compress the LH (Left Hand) secondary timing chain tensioner and remove the 303-1530.
1. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
79. Install the LH (Left Hand) upper primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
80. Rotate the crankshaft clockwise 60 degrees to the TDC (Top Dead Center) position (crankshaft dowel pin at 11 o'clock).
81. Install the crankshaft timing chain sprocket.
82. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT (Variable Camshaft Timing) assemblies and the crankshaft sprocket.
83. Install the lower LH (Left Hand) primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
84. Install the primary timing chain tensioner arm.
