Part 2
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Lower Engine Block (View 1)
Lower Engine Block (View 2)
NOTICE: 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, may cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Specifications.
NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G 372 BA or 1G 373 CA) and late build engines are built with engine code (1G 372 CA or 1G 373 DA).
41. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.
42. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).
43. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
44. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
45. NOTE: The valve tappets must be installed in their original positions.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
NOTE: LH shown, RH similar.
Install the valve tappets.
46. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
47. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
48. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
49. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
50. Loosen the 4 camshaft caps bolts.
51. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
52. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check Adjustments.
53. Remove the 3 bolts and the RH valve train oil tube.
54. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown.
55. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.
56. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
57. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
58. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
59. Loosen the 4 camshaft caps bolts.
60. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
61. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check Adjustments.
62. Remove the 3 bolts and the LH valve train oil tube.
63. Rotate the LH camshafts to the TDC position as shown.
64. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.
65. Using a new gasket, install the timing chain gear and the 9 bolts. Tighten in the sequence shown in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
66. Install the RH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
67. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
68. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.
69. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
70. Install the 2 new RH VCT bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
71. NOTE: The 2 VCT oil control solenoids are removed for clarity.
Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
- Make sure the secondary timing chain is centered on the timing chain tensioner guides.
72. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
73. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
- Align the colored links with the timing marks.
74. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
75. Install the 2 new LH VCT bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
76. NOTE: The 2 VCT oil control solenoids are removed for clarity.
Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
- Make sure the secondary timing chain is centered on the timing chain tensioner guides.
77. Install the upper LH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
78. Rotate the crankshaft clockwise to the TDC position (crankshaft dowel pin at 11 o'clock).
79. Install the crankshaft timing chain sprocket with timing dot mark out.
80. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
81. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
