Part 3
EngineAssembly (Steps 73-108)
73. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
74. Install 2 new M8 bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
75. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
76. Position the RH cassette and camshaft sprocket.
77. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install and hand-tighten the RH rear camshaft sprocket bolt.
78. Install the RH cassette bolt.
^ Tighten to 10 Nm (89 inch lbs.).
79. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
80. Install 2 new M8 bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
81. Tighten the 8 M 12 bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
82. Position the LH cassette and camshaft sprocket.
83. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install and hand-tighten the LH camshaft sprocket bolt.
84. Install the LH cassette bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
85. Turn the crankshaft one revolution clockwise.
86. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).
Install the special tool.
87. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.
Install the special tools on the front of the RH cylinder head.
88. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the rear of the RH cylinder head.
89. Install the special tool.
90. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt to 85 Nm (63 ft. lbs.).
91. Remove the special tool and install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
92. NOTE: Do not tighten the special tool top 2 clamp bolts. Camshaft sprocket must rotate freely.
Install the special tools on the front of the LH cylinder head.
93. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.
Install the special tools on the rear of the LH cylinder head.
94. Install the special tool.
95. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt to 85 Nm (63 ft. lbs.).
96. Install the LH camshaft tensioner.
97. Rotate the crankshaft until the cam lobe is in the up position.
98. NOTE: Lubricate the roller followers with clean engine oil.
Using the special tool, Install the roller followers in their original positions.
99. Position the RH engine mount bracket and install the 4 bolts.
^ Tighten to 80 Nm (59 ft. lbs.).
100. Position a new RH exhaust manifold gasket and the RH exhaust manifold. Install the 6 nuts.
^ Tighten to 23 Nm (17 ft. lbs.).
101. Position the LH engine mount bracket and install the 3 bolts.
^ Tighten to 80 Nm (59 ft. lbs.).
102. Position a new LH exhaust manifold gasket and the LH exhaust manifold. Install the 6 nuts.
^ Tighten to 23 Nm (17 ft. lbs.).
103. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil.
Position the oil level indicator tube and install the bolt.
^ Tighten to 11 Nm (8 ft. lbs.).
104. Clean the valve covers and cylinder head sealing surfaces with metal surface prep. Inspect and install new gaskets as necessary.
105. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
106. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
107. Position the thermostat housing, hoses and coolant tube. Install the 3 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
108. Connect the coolant hose to the coolant pump, position the bracket and install the bolt.
^ Tighten to 45 Nm (33 ft. lbs.).