Part 1
ENGINE - 3.0L (4V) ASSEMBLYAssembly
All Vehicles
Caution
^ During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
Caution
^ If the oil pan during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in oil leaks.
1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the crankcase cover, a new gasket and the bolts.
^ To install, tighten to 10 N-m (1.0 kgf-m, 89 in-lbf).
3. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 stages.
^ Stage 1: Tighten to 40 N-m (4.1 kgf-m, 30 ft-lbf).
^ Stage 2: Tighten 90 N-m (9.2 kgf-m, 66 ft-lbf)
^ Stage 3: Loosen one full turn.
^ Stage 4: Tighten to 40 N-m (4.1 kgf-m, 30 ft-lbf).
^ Stage 5: Tighten 90 degrees.
^ Stage 6: Tighten 90 degrees.
Note
^ LH shown, RH similar.
4. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
5. Install the hydraulic lash adjusters.
^ Lubricate the hydraulic lash adjusters with clean engine oil.
Caution
^ The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
Note
^ RH shown, LH similar.
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
Caution
^ The camshaft roller followers must be installed In their original positions. If not reassembled in their original positions, severe engine damage may occur.
Note
^ PH shown, LH similar.
8. Apply clean engine oil to the LH and RH camshafts.
9. Install the LH and RH camshafts.
^ Locate the camshafts as shown.
10. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.
Caution
^ Cylinder head camshaft journal caps and cylinder heads are numbered to verify they are assembled in their original positions. If not assembled in their original positions, severe engine damage may occur.
Caution
^ Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust bearing caps may occur.
11. Lubricate the bearing surfaces of the LH camshaft thrust bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.
12. Install the bolts.
^ Tighten in the sequence shown to 8 N-m (0.8 kgf-m, 71 in-lbf).
13. Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.
Caution
^ Cylinder head camshaft journal caps and cylinder heads are numbered to verify they are assembled in their original positions. If not assembled in their original positions, severe engine damage may occur.
Caution
^ Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been Installed, or damage to the thrust bearing caps can occur.
14. Lubricate the bearing surfaces of the RH camshaft thrust bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.
15. Install the bolts.
^ Tighten in the sequence shown to 8 N-m (0.8 kgf-m, 71 in-lbf).
16. Install the camshaft oil seal retainer and the 2 bolts.
^ To install, tighten to 10 N-m (1.0 kgf-m, 89 in-lbf).
Note
^ Clean the sealing surface with metal surface cleaner before installing a new press-in-place gasket.
17. Using the special tools, install a new camshaft seal.
Note
^ Apply clean engine oil to the seal lip and seal bore before installing the seal.
18. Remove the crankshaft pulley bolt.
19. Install the crankshaft sprockets with the timing marks out.
20. Position the chain tensioner in a soft-jawed vise.
Note
^ LH shown, RH similar.
21. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
Note
^ LH shown, RH similar.
22. Slowly compress the timing chain tensioner.
Caution
^ During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
23. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
24. If the timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
(1) Mark any link to use as the crankshaft timing mark.
(2) Starting with the crankshaft timing mark, count 29 links and mark the link.
(3) Continue counting to link 42 and mark the link.
25. Position the LH timing chain and guide and install the bolts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
26. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
(1) Install the tensioner arm.
(2) Position the tensioner.
(3) Install the bolts.
(4) Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
27. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
28. Verify that the RH camshafts are correctly positioned.
29. Position the RH timing chain and guide and install the bolts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
30. Install the RH timing chain tensioner arm and the RH timing chain tensioner.
(1) Install the tensioner arm.
(2) Position the tensioner.
(3) Install the bolts.
(4) Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
31. Remove the LH and RH timing chain tensioner piston retaining wires.
32. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
33. Verify the timing with the following steps.
(1) There should be 12 chain links between the camshaft timing marks.
(2) There should be 27 chain links between the camshaft and the crankshaft timing marks.
(3) There should be 30 chain links between the camshaft and the crankshaft timing marks.
Caution
^ Failure to verify correct timing drive component alignment will result in severe engine damage.
34. Remove the crankshaft pulley bolt.
35. Install the ignition pulse wheel.
Caution
^ This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).
36. Install 3 new gaskets in the front cover.
37. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
Note
^ Clean and degrease the sealing surfaces with metal parts cleaner before applying gasket and sealant.
Note
^ The front cover must be installed and bolts tightened within 4 minutes of sealant application.
38. Position the front cover and install the bolts and stud bolts.
^ Tighten the bolts in the sequence to 25 N-m (2.5 kgf-m, 18 ft-lbf).
Note
^ Fasteners 1 and 13 are stud bolts.
39. Using the special tools, install the crankshaft front oil seal.
Note
^ Apply clean engine oil to the seal lip and seal before installing the seal.
40. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
Note
^ Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealant.
^ Sealing surfaces must be free of dirt and oil.
^ The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
41. Using the special tool, install the crankshaft pulley.
Note
^ Lubricate the outside diameter sealing surface with clean engine oil.
42. Install the crankshaft pulley washer and bolt.
^ Tighten the crankshaft damper bolt in 4 stages.
^ Stage 1: Tighten to 120 N-m (12.2 kgf-m, 89 ft-lbf).
^ Stage 2: Loosen one full turn (360 degrees).
^ Stage 3: Tighten to 50 N-m (5.1 kgf-m, 37 ft-lbf).
^ Stage 4: Tighten to 90 N-m (9.2 kgf-m, 66 ft-lbf).