Part 2

3. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always use new bolts.

Install and tighten the RH head bolts in four stages in the sequence shown.
^ Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 ft. lbs.) and an additional 90 degrees.
^ Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.





4. Install and tighten the bolts in two stages.
1. Tighten to 20 Nm (15 ft. lbs.).
2. Tighten an additional 90 degrees.





5. Install and tighten the LH head bolts in four stages in the sequence shown.
^ Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 ft. lbs.) and an additional 90 degrees.
^ Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.





6. Install and tighten the bolts in two stages.
1. Tighten to 20 Nm (15 ft. lbs.).
2. Tighten an additional 90 degrees.

Items 9-15,17-23: RH and LH Camshaft Assembly Note








1. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.

NOTE: LH camshafts shown, RH camshafts similar.

Position the camshafts on the camshaft journals.
2. CAUTION: CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

Install the RH camshaft bearing caps.
^ Position the bearing caps.
^ Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown.
^ Stage 1: Hand-tighten.
^ Stage 2: Tighten to 6 Nm (53 inch lbs.).
^ Stage 3: Tighten an additional 90 degrees.





3. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

Install the LH camshaft bearing caps.
^ Position the bearing caps.
^ Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown.
^ Stage 1: Hand-tighten.
^ Stage 2: Tighten to 6 Nm (53 inch lbs.).
^ Stage 3: Tighten an additional 90 degrees.





4. CAUTION: If any components are installed new, the engine must be reshimmed or engine damage can occur.

Using a feeler gauge, confirm that the tappet and shim clearances are within specification.
5. If tappet and shim clearances are not within specification, adjust the clearance.
Item 24-52: Timing Drive Components Assembly Note
1. Install the engine lifting equipment and remove the engine from the stand.





2. NOTE: Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.

Using the special tools, install the rear main seal.





3. Install the flexplate and tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 110 Nm (81 ft. lbs.).
4. Mount the engine on a suitable engine stand and remove the engine lifting equipment.





5. Remove the crankshaft position (CKP) sensor and the torque converter cover.





6. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.

Install the special tool.
^ Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
^ Install the special tool.
7. Install the crankshaft sprocket.





8. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.





9. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.





10. Remove the locking pin from the LH secondary timing chain tensioner.





11. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.





12. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.





13. Remove the locking pin from the RH secondary timing chain tensioner.





14. Reset the timing chain tensioners.
1. Hold the lever toward the tensioner piston.
2. Using finger pressure, compress the tensioner.
3. Push the lever down and install a drill rod to lock the piston.





15. CAUTION: The camshaft holding tool should still be installed on the LH cylinder head.

CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the LH head.





16. Position the LH timing chain and crankshaft gear.
^ Position the timing chain over the LH intake camshaft sprocket.
^ Position the crankshaft gear in the timing chain.





17. Install the LH timing chain guide.





18. Install the LH timing chain tensioner arm.





19. Install the LH timing chain tensioner.
1. Install the timing chain tensioner and bolts.
2. Remove the drill rod.





20. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.

CAUTION: Using the special tool, apply 10 Nm (89 inch lbs.) counterclockwise to the LH exhaust camshaft sprocket.

Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





21. Remove the special tool.





22. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the right cylinder head.





23. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.





24. Install the RH timing chain guide.





25. Install the RH timing chain tensioner arm.





26. Install the RH timing chain tensioner.
1. Install the timing chain tensioner and bolts.
2. Remove the drill rod.





27. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.

CAUTION: Using the special tool, apply 10 Nm (89 inch lbs.) counterclockwise to the RH exhaust camshaft sprocket.

Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





28. Remove the special tool.





29. Remove the special tool.





30. Install the CKP sensor and the torque converter cover.

Items 53 and 56: Variable Cam Timing (VCT) Bush Carrier Assembly Note
1. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.

Item 59: Sump Body Assembly Note





1. CAUTION: 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 sump is not secured within four minutes of sealant application 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply three continuous beads of silicone gasket and sealant to the areas shown.





2. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in two stages.
^ Tighten the bolts to 15 Nm (11 ft. lbs.).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





3. Install a new gasket, the oil pump and the bolts.





4. NOTE: Inspect the O-ring. Install a new O-ring if necessary. Lubricate the O-ring with clean engine oil.

Install the oil pump screen cover and tube.

Items 60 and 61: Engine Front Cover Assembly Note





1. NOTE: If the front cover is not secured within four minutes of sealant application 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in eight places.





2. Install the engine front cover.
^ Install new gaskets.
^ Position the engine front cover on the cylinder block.
^ Loosely install the bolts.
^ Tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. NOTE: Lubricate the coolant pump O-ring seal with engine coolant. Use the same coolant that was drained from the engine.

Install the coolant pump.
^ Inspect the O-ring seal and install a new O-ring seal as necessary.
^ Position a new coolant pump gasket.
^ Position the coolant pump.
^ Install the bolts and tighten in two stages.
^ Stage 1: Tighten to 8 Nm (71 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.

Items 63-64 and 69-70: Exhaust Manifold Assembly Note





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

Install the exhaust manifold.
^ Install a new gasket and the exhaust manifold.
^ Tighten the eight nuts in the sequence shown.

Items 83-90: RH and LH Valve Cover Assembly Note





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

Inspect and install new gaskets as necessary.





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

NOTE: If the valve covers are not secured within four minutes of sealant application 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply four beads of silicone gasket and sealant as shown.





3. NOTE: RH is shown, LH is similar.
Install the valve covers.
^ Tighten the bolts in the sequence shown.

Items 92-94: Intake Manifold Assembly Note





1. Install new intake manifold gaskets.





2. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.

Install the intake manifold and tighten the bolts in the sequence shown.





3. Connect the throttle body heater hose.





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

Install the radio interference capacitor and the nut.

Item 105: Front Crankshaft Seal Assembly Note





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

Items 106-108: Crankshaft Pulley Assembly Note





1. NOTE: If the crankshaft pulley is not secured within four minutes of sealant application 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the crankshaft pulley keyway.





2. Using the special tool, install the crankshaft pulley.
3. Install the washer and a new bolt and tighten in two stages.
^ Stage 1: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 2: Tighten an additional 80 degrees.
^ Remove the flexplate holding tool.

Item 134: Engine Wiring Harness Assembly Note





1. Install the wiring harness onto the front cover.





2. Install the wiring harness onto the front cover.





3. Connect the crankshaft position (CKP) sensor electrical connector.





4. Install the exhaust gas oxygen sensor (H02S) connectors onto the brackets.





5. Connect the pin-type retainers.





6. Connect the A/C electrical connector and the retaining clip.





7. Connect the power steering pressure (PSP) switch.





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

Connect the variable cam timing (VCT) sensor electrical connector.





9. Install the nuts and the engine wiring harness retainer.





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

Connect the fuel injector and radio interference capacitor electrical connectors.





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

Connect the engine wiring harness retainers from the engine appearance cover support bracket.

Items 135 and 137: RH and LH Coil Cover Assembly Note





1. NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.

Lift up the wire harness and apply a 12.7 mm (0.5 inch) bead of silicone sealer in the notch of the valve cover.





2. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.





3. Install the coil cover.





4. Connect the wiring harness retainers to the RH valve cover.





5. Connect the wiring harness retainers to the RH valve cover.

Items 158 and 159: Oil Filter and Seal Assembly Note
1. Install the oil filter until the seal makes contact.
Tighten an additional 270 degrees.