Steps 41-80

Engine

















Engine Intake Components









Low End Components













Upper End Components













Major Exterior Components













Assembly


41. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.





42. Install the crankshaft sprocket, making sure the flange faces forward.





43. Install the lower end of the LH timing chain, aligning the timing marks.





44. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.





45. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





46. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.





47. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.





48. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





49. Remove the retaining clips from the RH and LH timing chain tensioners.





50. Check for correct alignment of all timing marks.





51. Install the crankshaft sensor ring on the crankshaft.





52. Lubricate the balance shaft journals with clean engine oil.

53. Position the balance shaft on the journals.





54. Align the timing mark on the balance shaft with the camshaft timing mark as shown.





55. Install the balance shaft bearing caps in their original locations and tighten the 6 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





56. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.

57. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.





58. NOTICE: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head Cylinder Head - Removal.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Position the cam lobe away from the camshaft roller follower prior to installing each camshaft roller follower.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.





59. Repeat the previous 3 steps for each of the camshaft roller followers.

60. NOTICE: 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 engine front cover is 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. Follow the directions on the packaging. 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.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.





61. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.





62. Tighten the 15 engine front cover fasteners in sequence in 2 stages.
- Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).









63. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.





64. NOTE: If the engine front cover is 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. Follow the directions on the packaging. 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.

NOTE: LH shown, RH similar.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.





65. Position the valve covers.

66. Tighten the 28 fasteners in the sequence shown.





67. Position the accessory drive belt idler pulley and install the bolt.
- Tighten to 25 Nm (18 lb-ft).





68. Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).





69. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the 3 bolts.

1. Tighten to 25 Nm (18 lb-ft).

2. Tighten to 10 Nm (89 lb-in).





70. NOTICE: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the coolant pump.

1. Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

2. Position the coolant pump into the engine block.

3. Install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





71. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





72. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





73. Using the Crankshaft Vibration Damper Installer, Crankshaft Front Oil Seal Installer and the Front Cover Oil Seal Installer, install a new crankshaft front seal.





74. NOTE: If the engine front cover is 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. Follow the directions on the packaging. 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





75. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





76. NOTE: Use a Strap Wrench (303-D055) or equivalent, to hold the pulley while tightening the bolt.

Tighten the new crankshaft pulley bolt in 4 stages.

- Stage 1: Tighten to 90 Nm (66 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft).





77. Position the RH engine support insulator and install the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).





78. Position the LH engine support insulator and install the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).





79. Install the radio frequency interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).





80. Position the engine control sensor wiring harness and connect all of the harness routing clips and connector retainers.