Part 3

Engine














Engine - Upper End














Engine - Front End














Engine - Lower End










51. Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






52. Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully closed.

53. Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.

54. Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






55. Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully closed.

56. Position the RH exhaust rocker arm shaft assembly and install the bolts finger-tight.

57. Tighten the 10 RH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






58. 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 6 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Follow the directions on the packaging. 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 and the oil pan-to-cylinder block surface, at the locations shown.






59. NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT (Variable Camshaft Timing) valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

Install new engine front cover gaskets on the engine front cover. With the VCT (Variable Camshaft Timing) variable force solenoid pins fully depressed, position the engine front cover onto the dowels. Install the fasteners finger-tight.






60. Tighten the 20 engine front cover fasteners in the sequence shown in 3 stages.
Stage 1: Tighten all fasteners to 10 Nm (89 lb-in).
Stage 2: Tighten all fasteners to 20 Nm (177 lb-in).
Stage 3: Tighten all fasteners an additional 45 degrees.











61. NOTE: If the rear crankshaft seal retaining plate is not secured within 6 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks.

Apply a bead of silicone gasket and sealant around the groove along the rear of crankshaft rear seal retainer plate sealing surface.






62. Install the crankshaft rear seal retainer plate and the 8 bolts in the sequence shown, in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






63. NOTE: If not secured within 6 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface and at the engine front cover-to-cylinder block sealing surface.






64. Position a new gasket and the oil pan and install the 20 bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 2 Nm (18 lb-in).

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

- Stage 3: Tighten an additional 45 degrees.







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





66. Using the Crankshaft Damper and Crankshaft Front Seal Installer and the Front Cover Oil Seal, install the new crankshaft front seal into the engine front cover.





67. NOTE: If not secured within 6 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.






68. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.





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





70. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 2 stages.
- Stage 1: Tighten to 175 Nm (129 lb-ft).

- Stage 2: Tighten an additional 90 degrees.






71. 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.

NOTE: Lubricate the new O-ring seal using clean engine coolant prior to installation.

Using a new O-ring seal, position the coolant pump and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 20 Nm (117 lb-in).

- Stage 2: Tighten an additional 45 degrees.






72. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






73. Install the heater coolant tube and the bolt.
- Tighten to 10 Nm (89 lb-in).






74. Install the 2 accessory drive idler pulleys, the coolant pump pulley and the 6 bolts.
- Tighten to 25 Nm (18 lb-ft).






75. 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 and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).