Part 2

46. 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.).

47. Remove the LH and RH timing chain tensioner piston retaining wires.

48. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).





49. 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.





50. Remove the crankshaft damper bolt.





51. 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.





52. Install the LH and RH spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).





53. Install 3 new gaskets in the engine front cover.

54. 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.





55. Position the engine front cover. Install the 14 bolts and the stud bolt.
^ Tighten in the sequence shown to 25 Nm (18 ft. lbs.).





56. Install the belt tensioner and the bolt.
^ Tighten to 48 Nm (35 ft. lbs.).





57. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.

Using the special tool, install a new crankshaft front seal.





58. NOTE: Clean the keyway and slot using metal surface cleaner 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.





59. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the special tools, install the crankshaft pulley.





60. 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.).





61. If equipped, install the block heater.
^ Tighten to 14 Nm (10 ft. lbs.).





62. Install the oil pressure sender.
^ Tighten to 14 Nm (10 ft. lbs.).





63. 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.





64. 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.).





65. Install the radio interference capacitor and the bolt.
^ Tighten to 8 Nm (71 inch lbs.).





66. Install the coolant bypass tube and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

67. NOTICE: The center coolant pump uses a sealing washer and must be replaced whenever the bolt is removed.

NOTE: The hole in the coolant pump for the center coolant pump bolt is threaded. Once the center coolant pump is unscrewed from the camshaft, it must also be unscrewed from the coolant pump.

remove the center coolant pump bolt from the coolant pump and discard the sealing washer.
^ Install a new sealing washer on the center coolant pump bolt, then install the center coolant pump bolt in the coolant pump.





68. Install the coolant pump and the 4 bolts. Tighten in 4 stages:
^ Stage 1: Tighten the coolant pump center bolt to 4 Nm (35 inch lbs.).
^ Stage 2: Loosely install the 3 coolant pump outer bolts.
^ Stage 3: Tighten the coolant pump center bolt to 25 Nm (18 ft. lbs.).
^ Stage 4: Tighten the 3 coolant pump outer bolts to 10 Nm (89 inch lbs.).





69. NOTE: Install a new O-ring seal on the thermostat housing and lubricate with clean engine oil

Install the thermostat housing and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).