Part 2
Engine
Engine - Upper End
Engine - Lower End
41. Remove the tensioner from the vise.
42. If the colored links are not visible, mark one link on one end and one link on the other end and use as timing marks.
43. Install the 4 bolts and the LH and RH timing chain guides.
- Tighten to 10 Nm (89 lb-in).
44. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single colored (marked) link on the chain.
45. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
46. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
47. Remove the retaining clip from the LH timing chain tensioner.
48. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single colored (marked) chain link.
49. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
50. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
51. Remove the retaining clip from the RH timing chain tensioner.
52. NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.
As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.
53. Install the crankshaft sensor ring on the crankshaft.
54. NOTE: Lubricate the roller followers with clean engine oil prior to installation.
Using the Valve Spring Compressor, install all of the camshaft roller followers.
55. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
56. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
57. Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
58. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
59. Using the Crankshaft Vibration Damper Installer, Crankshaft Front Oil Seal Installer and the Front Cover Oil Seal Installer, install the crankshaft front oil seal into the engine front cover.
60. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. 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 silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
61. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
62. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
63. NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
Slide the coolant tube forward with the new O-ring seals into the cylinder block.
64. Install the coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).
65. NOTICE: Do not rotate the coolant pump housing once the coolant pump housing has been positioned in the cylinder block. Damage to the O-ring seal will occur.
NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
Position the coolant pump and install the 4 bolts loosely.
66. Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).
67. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
68. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
69. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
70. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
71. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
72. Install the Knock Sensor (KS) and the bolts.
- Tighten to 20 Nm (177 lb-in).
73. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
74. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
75. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.
Position the RH valve cover and gasket on the cylinder head and tighten the 9 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
76. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
77. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
78. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.
Position the LH valve cover and gasket on the cylinder head and tighten the 10 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
79. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
80. Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
