Part 2
EngineAssembly (Steps 27-82)
27. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.
28. Install the RH camshaft drive cassette bolt and spacer.
^ Tighten to 18 Nm (13 lb-ft).
29. Install the front cassette and bolt.
^ Tighten to 19 Nm (14 lb-ft).
30. Position the jackshaft sprocket and chain.
31. Install the chain guide and bolts.
^ Tighten to 19 Nm (14 lb-ft).
32. Install the chain tensioner and the bolts.
^ Tighten to 9 Nm (80 lb-inch).
33. Install the bolt. Do not tighten at this time.
34. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt.
^ Tighten to 20 Nm (15 lb-ft).
35. Install the special tool on the rear of the jackshaft.
36. Tighten the rear bolt an additional 90 degrees.
37. Tighten the front bolt in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 lb-ft).
^ Stage 2: Tighten 90 degrees.
38. Remove the special tool and install the rear jackshaft plug.
39. Position the front cover gasket and install the front cover and the fasteners.
^ Tighten to 19 Nm (14 lb-ft).
40. CAUTION: Failure to back off the set screws may result in damage to the cylinder block cradle.
NOTE: The set screw is shown from the top (crankshaft) side of the cylinder block cradle.
Back the 8 set screws (7/16-inch Hex) off until they are below the cylinder block cradle boss.
41. NOTE: If the cylinder block cradle gasket is not secured within 4 minutes of the sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow the metal surface cleaner 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 silicone in the 6 places shown.
42. Position the cylinder block cradle and gasket assembly.
43. Install and hand-tighten the 20 bolts and 2 nuts.
44. Install and hand-tighten the rear cylinder block cradle bolts.
45. NOTE: The cylinder block cradle to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) cylinder block cradle underflush or 0.05 mm (0.002 inch) cylinder block cradle protrusion.
Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
46. Tighten the 20 bolts and 2 nuts.
^ Tighten the nuts to 10 Nm (89 lb-inch).
^ Tighten the bolts to 14 Nm (10 lb-ft).
47. Tighten the rear cylinder block cradle bolts.
^ Tighten to 9 Nm (80 lb-inch).
48. Tighten the 8 set screws (7/16-inch Hex).
^ Tighten to 3 Nm (27 lb-inch).
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 lb-ft).
^ Stage 2: Tighten to 33 Nm (24 lb-ft).
52. NOTE: The cylinder block cradle-to-cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) cylinder block cradle underflush or 0.05 mm (0.002 inch) cylinder block cradle protrusion.
Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
^ Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.
^ Cradles that exceed the underflush specification may be repaired by installing shims (next step).
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 lb-inch).
55. Install the gasket, oil pan and the bolts.
^ Tighten to 11 Nm (8 lb-ft).
56. Install the oil filter adapter.
^ Tighten to 57 Nm (42 lb-ft).
57. Position the coolant pump and install the bolts.
^ Tighten to 10 Nm (89 lb-inch).
58. NOTE: LH shown, RH similar.
Install the cylinder head gaskets.
59. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).
60. Install the 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).
61. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
62. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.
Install the RH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Stage 1:Tighten to 12 Nm (9 lb-ft).
^ Stage 2:Tighten to 25 Nm (18 lb-ft).
63. Install the 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).
64. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
65. Using the special tool, install the crankshaft pulley.
66. NOTE: 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 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
67. Position the RH camshaft sprocket in the chain and install it on the camshaft.
68. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the RH camshaft sprocket bolt.
69. Install the RH chain guide bolt.
^ Tighten to 10 Nm (89 lb-inch).
70. Position the LH camshaft sprocket in the chain and install it on the camshaft.
71. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the LH camshaft sprocket bolt.
72. Install the chain guide bolt.
^ Tighten to 12 Nm (9 lb-ft).
73. Turn the crankshaft one revolution clockwise.
74. 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 TDC.
Install the special tool.
75. 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.
76. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the rear of the RH cylinder head.
77. Install the special tool.
78. NOTE: 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 lb-inch).
2 Tighten the camshaft bolt to 85 Nm (63 lb-ft).
79. Install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 lb-ft).
80. 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.
81. 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.
82. Install the special tool.
