Part 1
ENGINE DISASSEMBLY AND ASSEMBLY ContinuedAssembly Note
Warning:
^ Failure to position the No. 1 piston at TDC can result in damage to the engine.
1. Using the damper bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center.
2. Remove the plug bolt.
3. Install the Engine Timing Peg ST 303-507.
^ Clean the oil pump gasket surface with metal surface cleaner.
4. Install a new gasket and the oil pump assembly. Tighten the bolts in the sequence in two stages.
^ Stage 1: Tighten the bolts to 10 Nm (1.0 kgf-cm, 80 inch lbs.).
^ Stage 2: Tight the bolts to 20 Nm (2.0 kgf-cm, 15 ft. lbs.).
Note:
^ Clean the oil pump pickup tube gasket 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. Install the rear main oil seal and tighten 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 gasket 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 these procedures can cause future oil leakage.
7. Apply a 2.5 mm bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the bolts in the sequence shown.
8. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
9. Clean the cylinder head gasket surface with metal surface cleaner.
10. Apply silicone gasket and sealant to the locations shown.
11. Install a new cylinder head gasket.
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.
12. Install the cylinder head. Tighten the bolts in the sequence shown in five stages.
^ Stage 1: Tighten the bolts to 5 Nm (0.5 kgf-cm, 44 inch lbs.)
^ Stage 2: Tighten the bolts to 15 Nm (1.5 kgf-cm, 11 ft. lbs.).
^ Stage 3: tighten the bolts to 45 Nm (4.5 kgf-cm, 33 ft. lbs.).
^ Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
^ Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
Caution:
^ Install the camshafts with the alignment notches 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.
13. 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 (0.7 kgf-cm, 62 inch lbs.).
^ Stage 3: Tighten the bolts to 16 Nm (1.6 kgf-cm, 12 ft. lbs.).
14. Install 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.
15. Tighten the oil pump sprocket bolt.
16. Install the oil pump chain guide and the shoulder bolt.
17. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
Note:
^ Sprockets must turn freely on the camshafts.
18. 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.
19. Using the edge of a vise, compress the timing chain tensioner plunger.
20. Using a small pick, push back and hold the ratchet mechanism.
21. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
22. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
23. Install the timing chain.
24. Install the timing chain guides.
25. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.