Part 2 of 3

Engine Assembly Continued (Part 2 of3)

41. NOTE: LH shown, RH similar.





Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

42. 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.





43. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.





44. If the timing marks on the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and the 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. Mark the link.





45. Position the LH timing chain and guide and install the bolts.
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





46. Install the LH timing chain tensioner and the tensioner arm.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the bolts.





47. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.





48. Verify that the RH camshafts are correctly positioned.





49. Install the RH timing chain and chain guide and install the bolts.
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





50. Install the RH timing chain tensioner and tensioner arm.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the bolts.
51. Remove the LH and RH timing chain tensioner piston retaining wires.
52. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).

53. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.





Verify the timing with these 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.





54. Remove the crankshaft damper bolt.

55. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30 RFF" only.





Install the ignition pulse wheel.





56. Install the LH and RH spark plugs.
57. Install new gaskets in the front cover.

58. NOTE: Clean and decrease the sealing surfaces with metal surface cleaner before applying gaskets and sealant.

NOTE: The front cover must be installed and the bolts tightened within four minutes of sealant application.





Apply a 6 mm (0.24 inch) dot of gasket and sealant to the cylinder block-to-lower cylinder block and the cylinder head mating surfaces.

59. NOTE: Fasteners No. 1 and 6 are studs.





Position the front cover and install the bolts and studs in the sequence shown.

60. NOTE: Clean all sealing surfaces with metal surface cleaner.

NOTE: Lubricate the front crankshaft seal before installation.





Using the special tool, install the crankshaft front oil seal.

61. NOTE: Inspect and install new O-rings as needed.

NOTE: Apply clean engine oil to aid in installation.





Install the coolant tube, the bolt and the stud.





62. Install the oil pressure sensor.





63. Install a new seal on the oil level indicator tube and apply clean engine oil.





64. Install the oil level indicator tube and install the bolt.





65. Apply clean engine oil to the oil filter O-ring and install a new oil filter.

66. NOTE: Clean the keyway and slot using metal surface cleaner before applying gasket sealer.

NOTE: The crankshaft damper must be installed and the bolt tightened within four minutes of sealant application.





Apply gasket and sealant to the end of the crankshaft damper keyway slot.





67. Using the special tool, install the crankshaft vibration damper.





68. Install the special tool to hold the flexplate.





69. Install the crankshaft vibration damper washer and bolt.
^ Tighten the bolt in four stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs.).
^ Stage 2: Loosen one full turn (360 degrees).
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten to 90 Nm (66 ft. lbs.).

70. NOTE: The pulley has LH threads.





Install the crankshaft pulley.

71. NOTE: Clean the valve cover sealing area using metal surface cleaner before installing a new gasket.

Install new gaskets in the valve covers.

72. NOTE: Clean the cylinder head and front cover surface using metal surface cleaner before applying silicone gasket and sealant.

NOTE: The valve cover must be installed and the bolts and spuds tightened within four minutes of sealant application.

NOTE: LH shown, RH similar.





Apply a 8 mm (0.31 inch) dot of gasket and sealant at the cylinder block-to-front cover mating surface of the LH and RH valve covers.





73. Position the RH valve cover and install the studs in the sequence shown.





74. Position the LH valve cover and install the studs in the sequence shown.





75. Install the coolant pump.
^ Position the coolant pump and install the mounting bolts.
^ Tighten the bolts in two stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.





76. Install the heater hose assembly and connect the heater hose to the coolant pump.





77. Connect the coolant pump outlet hose.





78. Connect the engine coolant temperature (ECT) sensor electrical connector and attach the pin-type retainer.

Vehicles with coolant pump belt tensioner





79. Rotate the drive belt tensioner clockwise and install the coolant pump belt.

Vehicles without coolant pump belt tensioner





80. Install the belt on the coolant pump pulley and position it on the camshaft pulley.