Part 3

Engine















Engine - Upper End















Engine - Lower End

















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, can cause engine failure.

NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Engine System - General Information Specifications.


61. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.

- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.





62. Install the LH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the LH VCT assembly.





63. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.





64. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain guide.

Install the LH timing chain guide and bolt.

- Tighten to 10 Nm (89 lb-in).





65. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain tensioner arm.

Install the LH timing chain tensioner arm.





NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.

66. NOTICE: Do not compress the ratchet assembly or damage to the tensioner will occur.

Compress the primary timing chain tensioner plunger, using an edge of a vise.





67. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.





68. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.





69. Install the LH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Remove the holding pin from the tensioner.





70. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.





71. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.

Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.





72. NOTE: Lubricate the camshafts with clean engine oil prior to installation.

Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.





73. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.





74. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time





75. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).

- Stage 2: Tighten an additional 45 degrees.





76. NOTE: Intake camshaft shown, exhaust camshaft similar.

Install the VCT system oil filter in the intake and exhaust camshafts.





77. Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.

1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.

2. The timing mark on the exhaust VCT assembly should align with the single colored link.





78. Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 1 o'clock position.





79. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.

- If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.





80. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts.

- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.





81. Install the RH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the RH VCT assembly.





82. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.





83. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain guide.

Install the RH timing chain guide and bolt.

- Tighten to 10 Nm (89 lb-in).





84. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain tensioner arm.

Install the RH timing chain tensioner arm.





85. Install the RH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Remove the holding pin from the tensioner.





86. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.





87. NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

NOTE: LH shown, RH similar.

Fully depress the VCT variable force solenoid pins.





88. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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 a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.





89. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Using new gaskets, position the engine front cover onto the dowels.

- Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts finger-tight.





90. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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.

Tighten the bolts in the sequence shown in 2 stages.

- Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).

- Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.