Part 2
EngineAssembly (Steps 15-47)
15. Install the bolt.
^ Tighten to 63 Nm (46 lb-ft).
16. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
Install the piston and connecting rod assemblies.
^ Use a piston ring compressor.
17. NOTE: Lubricate the connecting rod bearings with clean engine oil.
Install the connecting rod bearings.
18. Install the connecting rod caps and nuts.
^ Tighten to 35 Nm (26 lb-ft).
19. Install the oil pan baffle and nuts.
^ Tighten to 32 Nm (24 lb-ft).
20. Install the oil pump and bolt.
^ Tighten to 48 Nm (35 lb-ft).
21. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters.
22. Install the hydraulic lash adjuster guide plates.
23. Install the hydraulic lash adjuster guide plate retainer.
^ Tighten to 12 Nm (9 lb-ft).
24. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Install new head gaskets.
25. Install the cylinder heads.
26. Install the bolts. Tighten the bolts in the sequence shown in 5 stages.
^ Stage 1: Tighten to 50 Nm (37 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 30 Nm (22 lb-ft).
^ Stage 4: Tighten 90 degrees.
^ Stage 5: Tighten an additional 90 degrees.
27. Install a new oil filter.
28. NOTE: The end of the oil level tube should be cleaned with metal surface prep before application of the sealant.
Install the oil level indicator and tube assembly.
^ Coat the oil level indicator tube with silicone gasket and sealant.
29. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly, resulting in incorrect fuel injector timing and possible engine damage.
NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
Align the timing marks.
30. Install a new engine front cover gasket and the engine front cover.
31. Apply thread sealant with PTFE on the bolts to be installed in the locations shown.
32. Install the 10 bolts.
^ Tighten to 25 Nm (18 lb-ft).
33. Install the knock sensor (KS) and bolt.
^ Tighten to 25 Nm (18 lb-ft).
34. Install the crankshaft position (CKP) sensor and bolts.
^ Tighten to 10 Nm (89 lb-inch).
35. 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.
CAUTION: The thickness of the sealant must be between 4-6 mm (0.16-0.23 inch) or oil leaks may occur.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 4.0-6.0 mm (0.16-0.23 inch) bead of silicone gasket and sealant to the junction of the rear main bearing cap and the cylinder block, and to the junction of the front cover assembly and cylinder block.
36. Position a new oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
37. NOTE: Make sure the fasteners are clean and dry prior to installation.
Install the oil pan and bolts. Tighten in the sequence shown.
^ Tighten to 12 Nm (9 lb-ft).
38. Clean and inspect the exhaust manifolds.
39. Position a new exhaust manifold gasket and the LH exhaust manifold. Install new bolts and stud bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 10 Nm (89 lb-inch).
^ Stage 2: Tighten to 23 Nm (17 lb-ft).
40. NOTE: Do not tighten the exhaust manifold-to-EGR valve fitting at this time. The fitting will be tightened after the intake is installed and the other fitting is connected to the EGR valve
Position the exhaust manifold-to-EGR valve tube. Finger tighten the fitting.
41. Position a new exhaust manifold gasket and the RH exhaust manifold and install new bolts and stud bolts. Tighten the bolts and stud bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 10 Nm (89 lb-inch).
^ Stage 2: Tighten to 23 Nm (17 lb-ft).
42. Position the RH engine support insulator bracket and install the bolts.
^ Tighten to 48 Nm (35 lb-ft).
43. Position the LH engine support insulator bracket and install the bolt and the stud bolts.
^ Tighten to 48 Nm (35 lb-ft).
44. Position the starter splash shield and install the bolt and the nut.
^ Tighten to 10 Nm (89 lb-inch).
45. CAUTION: synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in incorrect fuel injector timing and possible engine damage.
CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the camshaft position (CMP) electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder. Failure to follow this procedure will result in incorrect fuel injector timing and possible engine damage.
Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
46. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment gauge is 38 degrees from the centerline of the engine.
47. Install the camshaft synchronizer retaining bolt.
^ Tighten to 30 Nm (22 lb-ft).
