Part 2
Engine
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.
NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G372 BA) and late build engines are built with engine code (1G372 CA).
All vehicles
46. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
47. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
48. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
49. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
50. Loosen the 4 camshaft caps bolts.
51. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
52. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check.
53. Remove the 3 bolts and the RH valve train oil tube.
54. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown.
55. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.
56. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
57. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the 4 camshaft seals gaps as shown.
58. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
59. Loosen the 4 camshaft caps bolts.
60. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
61. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check.
62. Remove the 3 bolts and the LH valve train oil tube.
63. Rotate the LH camshafts to the TDC position as shown.
64. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.
65. Using new gaskets, install the channel cover plate and the 9 bolts. Tighten in the sequence shown in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
66. Install the RH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
Engines with secondary timing chain tensioner removed
NOTICE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
67. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore.
NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.
Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
68. Install the RH secondary timing chain tensioner shoe.
69. Remove and discard the RH secondary timing chain tensioner shipping clip.
70. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.
71. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
72. Install the 2 new RH VCT bolts and tighten in 4 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
73. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
74. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Install the RH exhaust VCT oil control solenoid.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
75. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore.
NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.
Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
76. Install the LH secondary timing chain tensioner shoe.
77. Remove and discard the LH secondary timing chain tensioner shipping clip.
78. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
- Align the colored links with the timing marks.
79. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
80. Install the 2 new LH VCT bolts and tighten in 4 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
81. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
82. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Install the LH exhaust VCT oil control solenoid.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
Engines with secondary timing chain tensioner not removed
83. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
84. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.
85. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
86. Install the 2 new RH VCT bolts and tighten in 4 stages:
Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Loosen one full turn.
Stage 3: Tighten to 25 Nm (18 lb-ft).
Stage 4: Tighten an additional 180 degrees.
87. NOTE: The 2 VCT oil control solenoids are removed for clarity.
Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
- Make sure the secondary timing chain is centered on the timing chain tensioner guides.
88. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
89. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
- Align the colored links with the timing marks.
90. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
91. Install the 2 new LH VCT bolts and tighten in 4 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
