Part 2

Camshaft













Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

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, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain.


58. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

Install the fuel injection pump on the fuel injection pump mounting plate.





59. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.

NOTE: Start the fuel injection pump bolts by hand then simultaneously tighten to specifications.

Install the fuel injection pump and the 2 bolts.

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

- Tighten an additional 45 degrees.





60. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.

- Stage 1: Tighten to 32 Nm (24 lb-ft).

- Stage 2: Wait 10 minutes to minimize pre-stress.

- Stage 3: Tighten to 32 Nm (24 lb-ft).





61. Install the high-pressure fuel tube bracket nut.
- Tighten to 8 Nm (71 lb-in).





62. Attach the wiring harness retainers to the RH valve cover and stud bolt.

63. Connect the 3 RH ignition coil-on-plug electrical connectors.





64. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.





65. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Make sure the fuel rail wiring harnesses are routed correct.

NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





66. Connect the 2 turbocharger coolant hoses to the intake manifold.





67. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
- Tighten to 10 Nm (89 lb-in).





68. Attach the 2 wire harness-to-intake manifold retainers.





69. Connect the turbocharger wastegate regulating valve electrical connector.





70. Connect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.





71. Connect and attach the 2 fuel injector wiring harness electrical connectors.





72. Install the oil level indicator.





73. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
- Tighten to 8 Nm (71 lb-in).





74. Attach all the wiring harness retainers to the LH valve cover and stud bolts.

75. Install the engine cover mounting stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).





76. Install the lower radiator hose to the thermostat housing.





77. Connect the 3 LH ignition coil-on-plug electrical connectors.





78. Connect the Engine Oil Pressure (EOP) electrical connector.
- Attach the wiring harness retainer to the block.





79. Connect the LH VCT solenoid electrical connector.





80. Connect the Throttle Position (TP) and electronic Throttle Body (TB) electrical connectors.





81. Connect the fuel injection pump electrical connector and install the insulated cover.





82. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.

- Tighten to 6 Nm (53 lb-in).





83. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH turbocharger intake tube to the valve cover stud bolt and install the nut.

- Tighten to 6 Nm (53 lb-in).





84. NOTE: Align the index marks for the RH turbocharger intake pipe.

Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





85. NOTE: Align the index marks for the RH CAC tube.

Install the RH CAC tube to the RH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





86. Connect the RH turbocharger bypass valve electrical connector.





87. NOTE: Align the index marks for the LH turbocharger intake tube.

Install the LH turbocharger intake tube to the LH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





88. Install the turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC tube.





89. Connect the LH turbocharger bypass valve electrical connector.





90. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System - General Information Service and Repair.





91. Connect the brake vacuum tube to the intake manifold.





92. Using a new O-ring seal and gasket seal, connect the A/C tube to the compressor and install the nut.
- Tighten to 15 Nm (133 lb-in).





93. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System - General Information Service and Repair.





94. Raise the engine and transaxle assembly into the vehicle.

95. Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).





96. Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).





97. Install the bolt and the 3 nuts to the transaxle support insulator bracket-to-transaxle.
- Tighten the bolt to 80 Nm (59 lb-ft).

- Tighten the nuts to 63 Nm (46 lb-ft).





98. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.

Using a small screw driver, remove the compression seal and discard.





99. Using a soft-face hammer, install the new compression seal.





100. Position the PTU in place and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).





101. Position the PTU support bracket in place and install the 3 bolts.

1. Tighten the 2 bolts to 70 Nm (52 lb-ft).

2. Tighten the bolt to 48 Nm (35 lb-ft).





102. Install the RH halfshaft support bracket and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).





103. Install the RH turbocharger lower bracket and the 3 bolts and tighten in sequence shown.

1. Tighten the bolt to 19 Nm (168 lb-in).

2. Tighten the 2 bolts to 48 Nm (35 lb-ft).





104. Connect the transaxle cooler tubes and install the 2 secondary latches.





105. Connect the lower radiator hose to the radiator.





106. Attach the lower radiator hose retainer to the cooling fan and shroud.





107. NOTE: Align the index marks for the LH CAC tube.

Connect the lower LH CAC tube to the LH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





108. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.
- Tighten to 15 Nm (133 lb-in).





109. Install the A/C tube bracket and bolt to the rear of the A/C compressor.
- Tighten to 25 Nm (18 lb-ft).





110. Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.





111. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
- Tighten to 70 Nm (52 lb-ft).





112. Connect the fuel supply tube. For additional information, refer to Fuel System - General Information Service and Repair.





113. Install the Evaporative Emission (EVAP) tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information Service and Repair.





114. Connect the EVAP valve electrical connector and attach to the intake manifold.