Part 1
AssemblyAll vehicles
Warning: Failure to position the No. 1 piston at top dead center TDC can result in damage to the engine. Turn the engine in the normal direction of-rotation only.
1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
2. Remove the plug bolt.
Note: Only turn the engine in the normal direction of rotation.
Note: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
3. Install the special tool.
Note: Clean the sealing surface with metal surface cleaner.
4. Install the oil pump assembly and bolts. Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
Note: Clean the sealing surface with a metal surface cleaner.
5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.
6. Using the special tool, install the rear main oil seal.
7. Tighten the rear main oil seal bolts in the sequence shown.
Caution: 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 sealant.
Note: Clean the mating surface with metal surface cleaner.
Note: If the oil pan is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
8. Apply a 2.5 mm (0.1 inch) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan bolts in the sequence shown.
9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
Note: Clean the gasket surface with metal surface cleaner.
10. Apply silicone gasket and sealant to the locations shown.
11. Install a new cylinder head gasket.
12. Clean the cylinder head gasket surface with metal surface cleaner.
Note: The cylinder head must be secured within four minutes of silicone gasket application. If the cylinder head is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Note: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Note: Lubricate the cylinder head bolts with clean engine oil.
13. Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown in five stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 3: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees (1/4 turn).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn ).
Caution: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
Note: Lubricate the camshaft journals and bearing caps with clean engine oil.
14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
^ Stage 2: Tighten the bolts to 7 Nm (62 inch lbs.).
^ Stage 3: Tighten the bolts to 16 Nm (12 ft. lbs.).
Caution: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The diamond washers must be installed correctly, or severe engine damage can result.
15. Install the washers and the oil pump chain and sprockets.
^ The crankshaft sprocket flange must be facing away from the engine block.
Note: The oil pump chain sprocket must be held in place.
16. Tighten the oil pump sprocket bolt.
17. Install the oil pump chain guide and the shoulder bolt.
18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
Note: Sprockets must turn freely on the camshafts.
19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
Caution: Do not compress the ratchet assembly. This will damage the ratchet assembly.
20. Using the edge of a vise, compress the timing chain tensioner plunger.
21. Using a small pick, push back and hold the ratchet mechanism.
22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
24. Install the timing chain.
25. Install the timing chain guides.
26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
Caution: The special tool 303-465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage.
27. Install the special tool in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
Note: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
28. Tighten the camshaft sprocket bolts.
29. Clean the front cover gasket surface with metal surface cleaner.
30. Apply a 2.5 mm (0.1 inch) bead of silicone gasket and sealant to the front cover.
31. Apply silicone gasket and sealant to the locations shown.
Note: The front cover must be secured within four minutes of silicone gasket application. If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
32. Install the front cover. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the 8 mm bolts to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten the 10 mm bolts to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten the 13 mm bolts to 48 Nm (35 ft. lbs.).
Note: Do not reuse the crankshaft pulley bolt.
Note: Apply clean engine oil on the seal area before installing.