Steps 41-80

Engine

















Engine - Lower Engine Block (View 1)










Lower Engine Block (View 2)









Engine - Front Engine Block









Engine - Cylinder Head









Engine - Intake Manifold









NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.

NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley is loosened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage may occur.

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. For additional information, refer to Engine System - General Information Procedures.

41. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.





42. Using a small pick, push back and hold the ratchet mechanism.





43. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





44. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





45. Install the timing chain.





46. Position the timing chain guides and install the 2 LH guide bolts.
- Tighten to 10 Nm (89 lb-in).





47. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to apply tension to the timing chain.
- Tighten to 10 Nm (89 lb-in).





48. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.

Install the Camshaft Alignment Plate in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.





49. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.

NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.

Tighten the camshaft sprocket bolts.

- Tighten to 72 Nm (53 lb-ft).





50. 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: Clean the sealing surface with 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.

Clean the engine front cover gasket surface with silicone gasket remover and metal surface prep.

51. 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 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 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.





52. 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 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 silicone gasket and sealant to the locations shown.





53. 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.

Install the front cover. Tighten the bolts in the sequence shown in 3 stages.

- Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in).

- Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft).

- Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).





54. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the crankshaft front seal with clean engine oil.

Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.





55. NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil to the seal area prior to installing.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





56. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.





57. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

- Stage 1: Tighten to 100 Nm (74 lb-ft).

- Stage 2: Rotate an additional 90 degrees.





58. Remove the 6 mm x 18 mm bolt.





59. Remove the Crankshaft Timing Peg.





60. Remove the Camshaft Alignment Plate.





61. NOTE: Only turn the crankshaft in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turn.

62. Install the Crankshaft Timing Peg.





63. NOTE: Only turn the crankshaft in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.





64. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.

Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.

- If it is not possible to install the bolt, correct the engine timing.





65. Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, correct the engine timing.





66. Remove the Camshaft Alignment Plate.





67. Position a new Crankshaft Position (CKP) sensor and loosely install the 2 bolts.





68. Adjust the CKP with the Crankshaft Sensor Aligner, the tool must engage a tooth of the vibration damper, and tighten the 2 bolts.
- Tighten to 7 Nm (62 lb-in).





69. Remove the 6 mm x 18 mm bolt.





70. Remove the Crankshaft Timing Peg.





71. Install the timing peg plug.
- Tighten to 20 Nm (177 lb-in).





72. 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.

Clean the valve cover gasket sealing surface with 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.

73. 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 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 silicone gasket and sealant to the locations shown.





74. 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.

Install the valve cover and the 14 fasteners.

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





75. Install the following:

1. Crankshaft Position (CKP) sensor and the bolt
- Tighten to 7 Nm (62 lb-in).

2. Cylinder Head Temperature (CHT) sensor
- Tighten to 12 Nm (106 lb-in).

3. Spark plugs
- Tighten to 15 Nm (133 lb-in).





76. 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: Clean the sealing surface with 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.

NOTE: Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly.

Using a new O-ring seal, install the coolant pump and the 3 bolts.

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





77. Install the coolant pump pulley and the 3 bolts.
- Tighten to 20 Nm (177 lb-in).





78. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil prior to installation.

Using new O-ring seals, install the fuel rail and fuel injectors as an assembly, the ground strap and the bolt.

- Tighten the 2 fuel rail bolts to 25 Nm (18 lb-ft).

- Tighten ground strap bolt to 10 Nm (89 lb-in).





79. Install the left motor mount and the 4 bolts.
- Tighten to 49 Nm (36 lb-ft).





80. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator, the KS and the 9 bolts.

- Tighten the KS bolt to 20 Nm (177 lb-in).

- Tighten the 8 crankcase vent oil separator bolts to 10 Nm (89 lb-in).