Part 2

Engine

Engine Component View (Part 1):

Engine Component View (Part 4):

Engine Component View (Part 7):

Engine Component View (Part 9):

Engine Component View (Part 10):

Engine Component View (Part 12):

Engine Component View (Part 13):

Engine Component View (Part 14):

Assembly (Steps 41-80)
41. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.





42. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





Engines with ratcheting timing chain tensioners

43. Remove the retaining clip from the LH timing chain tensioner.





Engines with non-ratcheting timing chain tensioners

44. Remove the retaining clip from the LH timing chain tensioner.





All engines

45. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.





46. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.





47. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





Engines with ratcheting timing chain tensioners

48. Remove the retaining clip from the RH timing chain tensioner.





Engines with non-ratcheting timing chain tensioners

49. Remove the retaining clip from the RH timing chain tensioner.





All engines

50. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.





51. Rotate and camshaft until the lobe is in the upward position.





52. Install the special tool between the valve spring coil to prevent valve stem seal damage.





53. NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the 16 camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the 16 camshaft roller followers in their original locations.





54. Remove the special tool.





55. CAUTION: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.

Install all 8 spark plugs.
^ Tighten to 18 Nm (13 ft. lbs.).





56. Install the crankshaft sensor ring.





57. CAUTION: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

NOTE: RH timing chain removed for clarity.

Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.





58. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.





59. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).











60. NOTE: RH shown, LH similar.

Install the RH and LH engine mounts and the 6 bolts.
^ Tighten to 70 Nm (52 ft. lbs.).





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





62. Using the special tools, install the front oil seal.





63. CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. 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.

Apply sealant to the Woodruff key slot on the crankshaft pulley.





64. Using the special tool, install the crankshaft pulley.





65. NOTE: Use a suitable strap wrench to hold the pulley.

Tighten the crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Rotate an additional 90 degrees (1/4 turn).





66. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal may cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring seal. Lubricate the O-ring seal with clean engine oil.

Install the oil pump screen and pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).





67. Position the oil pump screen and pickup tube, and install the 3 bolts.
1. Tighten to 25 Nm (18 ft. lbs.).
2. Tighten to 10 Nm (89 inch lbs.).





68. Install the new oil filter adapter gasket, oil filter adapter and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.





69. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the coolant pump.
1. Lubricate the new O-ring seal using engine coolant.
2. Position the coolant pump into the engine block.
3. Install the 4 bolts and tighten to 25 Nm (18 ft. lbs.).





70. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





71. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





72. CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply sealant in 2 places where the engine front cover meets the cylinder head.





73. Install the new LH gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





74. CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply sealant in 2 places where the engine front cover meet the cylinder head.





75. Install the new RH gasket into the valve cover and position on the cylinder head. Tighten the 11 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





76. Install the knock sensor (KS) and the nut.
^ Tighten to 20 Nm (15 ft. lbs.).





77. Inspect the O-rings seals. Install new seals if necessary.





78. Install the coolant bypass tube.





79. Install the ground strap on the rear of the RH cylinder head.
1. Install the stud bolt and tighten to 25 Nm (18 ft. lbs.).
2. Install the ground strap.
3. Install the retaining nut and tighten to 10 Nm (89 inch lbs.).





80. NOTE: Align the gasket locator tabs to slots in cylinder head.

Install the new intake manifold gaskets, intake manifold and hand-tighten the 8 bolts at the locations shown.