Part 2

Cylinder Head















41. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.






42. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.





43. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time





44. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).

- Stage 2: Tighten an additional 45 degrees.






45. NOTE: Intake camshaft shown, exhaust camshaft similar.
Install the VCT (Variable Camshaft Timing) system oil filter in the intake and exhaust camshafts.






46. Install the secondary timing chain onto the RH VCT (Variable Camshaft Timing) assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT (Variable Camshaft Timing) assemblies as shown in the illustration.
1. The timing mark on the intake VCT (Variable Camshaft Timing) assembly should align between the 2 consecutive colored links.

2. The timing mark on the exhaust VCT (Variable Camshaft Timing) assembly should align with the single colored link.






47. Install the RH VCT (Variable Camshaft Timing) assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT (Variable Camshaft Timing) assembly should be in the 1 o'clock position.





48. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT (Variable Camshaft Timing) assemblies onto the camshafts.
Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT (Variable Camshaft Timing) assemblies onto the camshafts.

- If the secondary timing chain is not centered over the tensioner, reposition the VCT (Variable Camshaft Timing) assemblies until they are fully seated on the camshafts.






49. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT (Variable Camshaft Timing) assembly bolts.
Install the 3 RH intake VCT (Variable Camshaft Timing) assembly bolts and the 3 RH exhaust VCT (Variable Camshaft Timing) assembly bolts.

- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.






All cylinder heads

50. Install the RH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the RH VCT (Variable Camshaft Timing) assembly.






51. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.





52. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain guide.
Install the RH timing chain guide and bolt.

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






53. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain tensioner arm.
Install the RH timing chain tensioner arm.






54. Install the RH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Remove the holding pin from the tensioner.






55. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.





56. 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.
NOTE: LH shown, RH similar.
Fully depress the VCT (Variable Camshaft Timing) variable force solenoid pins.






57. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.






58. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Using new gaskets, position the engine front cover onto the dowels.

- Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and 2 oil pan-to-engine front cover stud bolts finger-tight.






59. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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. Failure to follow this procedure can cause future oil leakage.
Tighten the bolts in the sequence shown in 2 stages.

- Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).

- Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.






60. Using a 10 mm Hex Bit, rotate the engine front cover jackscrew into contact with the oil filter adapter to 5 Nm (44 lb-in).





61. Install the engine front cover-to-oil filter adapter bolt and tighten to 25 Nm (18 lb-ft) plus an additional 60 degrees.





62. Position the wiring harness and install the wiring harness retainer to the oil pan stud bolt.





63. NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.
Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.






64. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.






65. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.





66. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.





67. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 140 Nm (103 lb-ft).

- Stage 2: Loosen 360 degrees.

- Stage 3: Tighten to 100 Nm (74 lb-ft).

- Stage 4: Tighten an additional 90 degrees.






68. Install the generator and the 2 bolts.
- Tighten to 48 Nm (35 lb-ft).






69. Connect the wiring harness connector to the generator.
- Install the B+ wire and nut onto the generator.
- Tighten to 17 Nm (150 lb-in).







70. Install the ground wire and nut to the engine front cover stud bolt.
- Tighten to 10 Nm (89 lb-in).






71. Attach the wiring harness retainer to the engine front cover stud bolt.





72. Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).






73. NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.
Using a new O-ring seal, install the coolant pump and the 4 bolts.

- Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.






74. Install the coolant pump pulley and the 4 bolts.





75. Rotate the A/C compressor belt tensioner clockwise and install the A/C compressor belt.





76. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.





77. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).





78. NOTE: Lubricate the new thermostat housing O-ring seal with clean engine coolant.
Using a new thermostat housing O-ring seal, install the thermostat housing and the 2 bolts.

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






79. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.






80. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) variable force solenoid seal(s).






81. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.






82. Position the LH valve cover and new gasket on the cylinder head.
- Tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).






83. Install the oil level indicator.

84. If removed, install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Connect the LH intake and exhaust CMP (Camshaft Position) sensor electrical connectors.






85. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.






86. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) variable force solenoid seal(s).






87. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.






88. Position the RH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).






89. If removed, install the RH intake and exhaust CMP (Camshaft Position) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Connect the RH intake and exhaust CMP (Camshaft Position) sensor electrical connectors.






90. Connect the 2 VCT (Variable Camshaft Timing) variable force solenoid electrical connectors.
- Attach the 10 wiring harness retainers to the LH valve cover.






91. Connect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
- Attach the 10 wiring harness retainers to the RH valve cover.






92. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.






93. NOTE: RH shown, LH similar.
NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown, LH similar.

Install the 8 ignition coils and 8 bolts.
- Tighten to 6 Nm (53 lb-in).






94. NOTE: RH shown, LH similar.
Connect the 8 ignition coil electrical connectors.






95. Install the engine. For additional information, refer to Engine Removal.