Part 2

Engine














Upper End Components and Front End Accessory Drive (FEAD) Components










Lower End Components and Coolant Pump










Oil Filter Adapter Assembly










Timing Drive Components and Cylinder Heads










Flywheel and Exhaust Manifolds









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play.

35. Install the LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






36. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.





37. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.





38. Install the LH primary timing chain tensioner arm.





39. Install the LH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

- Remove the pin from the tensioner.






40. Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






41. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.





42. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.





43. Install the RH primary timing chain tensioner arm.





44. Install the RH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

- Remove the pin from the tensioner.






45. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.





46. Install the crankshaft washer.





47. Install the crankshaft sensor ring.





48. NOTICE: If the components are to be reinstalled, they must be installed in their original positions or damage to the engine may occur.

Install the hydraulic lash adjusters.






49. Using the Valve Spring Compressor, compress the valve spring and install the roller follower.





50. Repeat the previous step to install all the roller followers.

51. NOTE: RH shown, LH similar.
Install the 8 spark plugs.

- Tighten to 18 Nm (159 lb-in).


52. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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 a bead of silicone sealer to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.






53. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.
Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:
Bolts 1 through 14 to 25 Nm (18 lb-ft).
Bolts 15 and 16 to 50 Nm (37 lb-ft).









54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





55. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.





56. 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 Woodruff key slot on the crankshaft pulley.






57. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.





58. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





59. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 90 Nm (66 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90 degrees.






60. Install the coolant pump and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).






61. Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






62. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






63. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.





64. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. 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.

NOTE: LH shown, RH similar.
Apply silicone gasket and sealant to the engine front cover-to-cylinder block joints.






65. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. 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.

NOTE: RH shown, LH similar.

Install the valve covers, bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






66. NOTE: LH shown, RH similar.
If equipped, install the LH and RH block drain plugs.

- Tighten to 14 Nm (124 lb-in).






67. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator.

- Tighten to 10 Nm (89 lb-in).






68. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Using a new gasket, install the oil filter adapter and the 8 bolts.

- Tighten in the sequence shown:
- Bolts 1 through 6 to 25 Nm (18 lb-ft).

- Bolts 7 and 8 to 50 Nm (37 lb-ft).






69. NOTICE: A new cooler must be installed or severe damage to the engine can occur.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using new gaskets, install a new oil cooler and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






70. Install the coolant tube assembly and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






71. Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).






72. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).


73. Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).






74. Install the LH engine support insulator bracket and the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).