Part 2
EngineAssembly (Steps 46-90)
46. NOTE: The 20 bolts may or may not have washers. All the bolts should be of the same type.
Tighten the 20 bolts and 2 nuts.
^ Tighten bolts with washers and nuts to 10 Nm (89 inch lbs.).
^ Tighten bolts without washers to 14 Nm (10 ft. lbs.).
47. Tighten the rear cylinder block cradle bolts.
^ Tighten to 9 Nm (80 inch lbs.).
48. Tighten the 8 set screws (7/16-inch Hex).
^ Tighten to 3 Nm (27 inch lbs.).
49. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.
50. Position the 6 remaining bolts.
51. Tighten the cylinder block cradle inner bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 33 Nm (24 ft. lbs.).
52. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.
Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
53. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.
54. Install the oil pump screen cover and tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
55. Install the gasket, oil pan and the bolts.
^ Tighten to 9 Nm (80 inch lbs.).
56. Install the oil filter adapter.
^ Tighten to 57 Nm (42 ft. lbs.).
57. Install a new oil filter.
^ Tighten to 13 Nm (10 ft. lbs.).
58. Position the coolant pump and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
59. NOTE: LH shown, RH similar.
Install the cylinder head gaskets.
60. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.
NOTE: Late build shown, early build similar.
Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Tighten to 12 Nm (9 ft. lbs.).
^ Tighten to 25 Nm (18 ft. lbs.).
61. NOTE: Late build shown, early build similar.
Install the 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
62. NOTE: Late build shown, early build similar.
Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
63. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.
NOTE: Late build shown, early build similar.
Install the RH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Tighten to 12 Nm (9 ft. lbs.).
^ Tighten to 25 Nm (18 ft. lbs.).
64. NOTE: Late build shown, early build similar.
Install the 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
65. NOTE: Late build shown, early build similar.
Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
66. Using the special tool, install the crankshaft pulley.
67. CAUTION: A new bolt must be used each time it is removed.
Install the crankshaft pulley bolt and tighten in 2 stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
68. Position the RH camshaft sprocket in the chain and install it on the camshaft.
69. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the RH camshaft sprocket bolt.
70. Install the RH chain guide bolt.
^ Tighten to 10 Nm (89 inch lbs.).
71. Position the LH camshaft sprocket in the chain and install it on the camshaft.
72. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the LH camshaft sprocket bolt.
73. Install the chain guide bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
74. Turn the crankshaft one revolution clockwise.
75. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).
Install the special tool.
76. NOTE: Camshaft timing slots are off-center.
Position the camshaft timing slots below centerline of camshaft and install the special tools on the front of the RH cylinder head.
77. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the rear of the RH cylinder head.
78. Install the special tool.
79. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Tighten the bolts.
1. Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2. Tighten the camshaft bolt to 85 Nm (63 ft. lbs.).
80. Install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
81. NOTE: Do not tighten the special tool top 2 clamp bolts. Camshaft sprocket must rotate freely.
Install the special tools on the front of the LH cylinder head.
82. NOTE: Camshaft timing slots are off-center.
Position the camshaft timing slots below centerline of camshaft and install the special tools on the rear of the LH cylinder head.
83. Install the special tool.
84. Tighten the bolts.
1. Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2. Tighten the camshaft bolt.
^ Tighten to 85 Nm (63 ft. lbs.).
85. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
86. NOTE: Late build shown, early build similar. Rotate the crankshaft until the cam lobe is in the UP position.
87. NOTE: Lubricate the parts with clean engine oil prior to installing.
Using the special tool, install the roller followers in their original positions.
88. Inspect the LH and RH exhaust manifold gasket mating surface for flatness.
89. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
90. Install a new gasket, the LH exhaust manifold and new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).