Steps 1 - 47
ASSEMBLYEngine
Special Tools And Equipment, Part 1:
Special Tools And Equipment, Part 2:
Special Tool(s)
Material, Part 1:
Material, Part 2:
Material
CAUTION: 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.
1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the oil separator cover, a new gasket and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
3. Install the power steering pump bracket and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
4. NOTE: RH shown; LH similar.
Position the gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 3: Loosen 1 full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten 90 degrees.
^ Stage 6: Tighten 90 degrees.
5. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. CAUTION: The camshaft roller followers must be installed in their original positions.
NOTE: RH shown; LH similar.
Install the LH and RH camshaft roller followers.
8. Apply clean engine oil to the LH and RH camshafts.
9. Install the LH and RH camshafts.
^ Locate the camshafts as shown.
10. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
Lubricate the camshaft journal caps with clean engine oil. Position the LH camshaft caps and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
11. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
Position the RH camshaft caps and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
12. NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
Install the camshaft oil seal retainer and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
13. NOTE: Lubricate the camshaft oil seal with clean engine oil.
Position the new camshaft oil seal on the special tool.
14. Position the special tool and the camshaft oil seal on the camshaft.
15. Using the special tools, install the camshaft oil seal.
16. Remove the crankshaft damper bolt.
17. Install the crankshaft sprocket with the timing marks facing outward.
18. NOTE: LH shown; RH similar.
Position the chain tensioner in a soft-jawed vise.
19. NOTE: LH shown; RH similar.
Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
20. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
Slowly compress the timing chain tensioner.
21. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.
22. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1 Mark any link to use as the crankshaft timing mark.
2 Starting with the crankshaft timing mark, count 29 links and mark the link.
3 Continue counting to link 42 and mark the link.
23. Verify that the LH camshafts are correctly positioned.
24. Position the LH timing chain and guide and install the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
25. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
26. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
27. Verify that the RH camshafts are correctly positioned.
28. Install the RH timing chain and chain guide and install the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
29. Install the RH timing chain tensioner and tensioner arm.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
30. Remove the LH and RH timing chain tensioner piston retaining wires.
31. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
32. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
Verify the timing with the following steps.
1 There should be 12 chain links between the camshaft timing marks.
2 There should be 27 chain links between the camshaft and the crankshaft timing marks.
3 There should be 30 chain links between the camshaft and the crankshaft timing marks.
33. Remove the crankshaft damper bolt.
34. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).
Install the ignition pulse wheel.
35. Install the LH and RH spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).
36. Install 3 new gaskets in the engine front cover.
37. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
Apply a 6 mm (0.24 inch) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
38. Position the engine front cover. Install the 14 bolts and the stud bolt.
^ Tighten in the sequence shown to 25 Nm (18 ft. lbs.).
39. Install the belt tensioner and the bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
40. Using the special tool, install a new crankshaft front seal.
41. NOTE: Clean the keyway and slot using silicone gasket remover and metal surface prep before applying silicone gasket and sealant.
NOTE: The crankshaft damper must be installed and the bolt tightened within 4 minutes of sealant application.
Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
42. Using the special tools, install the crankshaft pulley.
43. Using the special tool to hold the crankshaft pulley, install the bolt and washer and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs.).
^ Stage 2: Loosen 1 full turn (360 degrees).
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten to 90 Nm (66 ft. lbs.).
44. If equipped, install the block heater.
^ Tighten to 14 Nm (10 ft. lbs.).
45. Install the oil pressure sender.
^ Tighten to 14 Nm (10 ft. lbs.).
46. Install the oil pan baffle and the 8 nuts.
^ Tighten the M8 nuts to 15 Nm (11 ft. lbs.) and then rotate 45 degrees.
^ Tighten the M6 nuts to 5 Nm (44 inch lbs.) and then rotate 45 degrees.
47. NOTE: Lubricate the new oil pump screen and pickup tube O-ring seal with clean engine oil.
Position the oil pump screen and pickup tube and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).