Part 2 of 3

Items 20-33: Timing Drive Components Assembly Note





1. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1 Mark any link to use as the exhaust camshaft timing mark.
2 Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark.
3 Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.





2. Verify that the crankshaft keyway is in the eleven o'clock position.





3. CAUTION: The crankshaft keyway must remain in the eleven o'clock position until the cams are located in the neutral position, or damage to the valves can occur.

Rotate the LH and RH intake and exhaust camshafts to locate them in their neutral positions.





4. NOTE: Gold colored bolt must be installed in its original location.

Install the LH VCT solenoid housing assembly and the bolts.





5. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.





6. Install the LH timing chain tensioner arm.





7. NOTE: Be sure to position the tensioner so that the tensioner piston is fully engaged in the tensioner arm.

Install the LH timing chain tensioner and bolts.





8. Remove the wire or paper clip from the tensioner.





9. Rotate the crankshaft clockwise and position the keyway at the three o'clock position for RH timing chain installation.





10. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing index marks on the camshaft and crankshaft sprockets.





11. Install the RH VCT solenoid housing assembly and bolts.





12. Install the RH timing chain, aligning the copper (or marked) links with the marks on the camshaft and crankshaft sprockets.





13. Verify that the copper or (marked) links on the RH timing chain are in alignment with the timing marks on the camshaft and crankshaft sprockets.





14. Install the RH timing chain tensioner arm.





15. Install the RH timing chain tensioner and bolts.





16. Remove the wire or paper clip from the RH timing chain tensioner.





17. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.

Items 20 and 27: VCT System Oil Filters Assembly Note





1. NOTE: LH is shown, RH is similar.

Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.





2. Remove the VCT system filter cap and replace the VCT system filter.
3. Repeat the previous steps for the RH VCT system filter.

Items 34 and 35: Engine Front Cover and Front Cover Gaskets Assembly Note





1. Clean the engine front cover to cylinder block and cylinder head sealing surfaces, using a clean shop towel and metal surface cleaner to remove all residue.
2. Install new front cover seals into the front cover.





3. NOTE: Install the engine front cover and bolts no more than four minutes after applying sealer.

Apply a 6 mm (0.24 inch) diameter dot of silicone gasket and sealant to the areas shown.





4. NOTE: Fastener No. 14 is a stud bolt.

Install the engine front cover and the bolts.
- Tighten the bolts in the sequence shown.

Items 36-39: Oil Pan Gasket, Oil Pan, Oil Pan Stud and Bolts Assembly Note
1. Rotate the engine upside down on the engine stand.
2. Clean the oil pan-to-cylinder block sealing surfaces on the oil pan and cylinder block with a clean shop towel and metal surface cleaner to remove all residue.





3. NOTE: Install the oil pan and bolts no more than four minutes after applying sealer.

Apply a 10 mm (0.4 inch) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the two locations shown.





4. NOTE: The oil pan rear face must be installed flush to the cylinder block rear face to within ± 0.10 mm (0.0039 inch). Failure to maintain this specification will require the oil pan to be removed and installed again.

Install the oil pan.
- Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.





5. Tighten the oil pan bolts in the sequence shown.

Items 40 and 41: RH Valve Cover and Gaskets Assembly Note
1. Install a new gasket in the RH valve cover.





2. NOTE: Install the valve cover and bolts no more than four minutes after applying the sealer.

Apply an 8 mm (0.32 inch) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.





3. Position the RH valve cover and install the bolts in the sequence shown.

Items 44 and 45: LH Valve Cover and Gaskets Assembly Note
1. Install a new gasket in the LH valve cover.





2. NOTE: Install the valve cover and bolts no more than four minutes after installing the sealer.

Apply an 8 mm (0.32 inch) bead of silicone gasket and sealer to the cylinder half round surface and to the front cover gasket intersection places.





3. Position the LH valve cover and install the bolts in the sequence shown.

Items 47-49: Lower Intake Manifold Assembly, Gaskets and Bolts Assembly Note





1. Inspect the lower intake manifold gaskets. Install new gaskets if necessary.





2. Position the lower intake manifold assembly and install the bolts in the sequence shown.

Items 57 and 58: RH Exhaust Manifold and Nuts Assembly Note





1. Position the RH engine mount bracket and install the bolts.





2. Using a new gasket, position the RH exhaust manifold and install the nuts.

Items 68: Oil Filter Assembly Note
1. Using an oil filter strap wrench, install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Item 77: Crankshaft Front Oil Seal Assembly Note





1. Using the special tool, install the crankshaft front oil seal.

Items 78-80: Crankshaft Pulley, Bolt, and Washer Assembly Note





1. NOTE: Install the crankshaft damper no more than four minutes after applying the sealer.

Apply a dot of silicone gasket and sealant to the crankshaft damper keyway slot.





2. Using the special tool, install the crankshaft damper.





3. Using the special tool, install the washer and a new bolt.
Tighten the bolt in four stages:
- Stage 1: Tighten to 120 Nm (89 ft. lbs.)
- Stage 2: Back out a minimum of one full turn (360 degrees).
- Stage 3: Tighten to 50 Nm (37 ft. lbs.)
- Stage 4: Tighten an additional 90 degrees.

Items 81 and 82: LH Exhaust Manifold and Nuts Assembly Note





1. Position the LH engine mount bracket and install the bolts.





2. Using a new gasket, position the LH exhaust manifold and install the nuts.

Items 92 - 99: Upper Intake Manifold, Gaskets and Bolts, and Fuel Regulator Shield and Bolts Assembly Note





1. Position the upper intake manifold and gaskets. Install the bolts finger tight.
2. Position the fuel pressure sensor shield and install the bolts finger tight.





3. Tighten the upper intake bolts in the same sequence shown.

Item 104: Engine Wiring Harness Assembly Note





1. Position the ground strap and install the nut.





2. Install the bracket and the nut.





3. Position the wiring harness and install the four nuts.





4. Position the two radio ignition interference capacitors and install the bolts.





5. Attach the wiring harness retainer.





6. Clip the two wiring harness retainers into the brackets and connect the generator electrical connector.





7. Position the wiring harness and install the nut.





8. Attach the three wiring harness retainers.





9. Attach the three wiring harness retainers.





10. Connect the A/C electrical connector.





11. Connect the oil pressure switch electrical connector.





12. NOTE: LH is shown, RH is similar.

Connect the two Camshaft Position (CMP) sensor electrical connectors.





13. Connect the Crankshaft Position (CKP) sensor electrical connector.





14. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





15. Connect the fuel injector wiring harness connector.





16. Connect the intake manifold tuning valve electrical connectors.





17. Connect the throttle body electrical connectors.

Item 106: Emissions Vacuum Hose Assembly Note





1. Connect the fuel pressure sensor jumper to the main vacuum harness.
2. Connect the Positive Crankcase Ventilation (PCV) tube at the rear of the upper intake manifold.

Item 125: Crankshaft Rear Oil Seal Assembly Note
1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.





2. Using the special tools, install the crankshaft rear oil seal.

Items 126-128: Flexplate Bolts, Flexplate, and Spacer Plate Assembly Note





1. Install the special tool onto the engine as shown.





2. Install the special tool onto the engine as shown.
3. Using the special tool and an engine crane, transfer the engine from the stand to the floor or a bench.





4. Install the spacer plate assembly.





5. Attach both the wiring harness retainers, one on each side of the engine.





6. Install the flywheel and the bolts.