Part 1
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ENGINE ASSEMBLY - 3.0L
Part 1 of 2
Assembly
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 Nm {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 Nm {4.1 kgf-m, 30 ft-lbf}.
- Stage 2: Tighten 90 Nm {9.2 kgf-m, 66 ft-lbf}.
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm {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.
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:RH shown, LH similar.
8. Install the new LH and RH oil filter screens in the intake camshafts.
NOTE:RH shown, LH similar.
9. Position the camshaft phaser and sprockets onto the intake camshafts.
- Install the 3 bolts finger-tight.
10. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
- Align the LH camshafts as shown.
11. 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 that they are assembled in their original positions. If not reassembled 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 caps can occur.
12. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
- Loosely install the bolts.
13. Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
14. Lubricate the bearing surfaces of the RH camshaft thrust bearing caps with clean engine oil and install the bearing caps.
- Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm {1.8 kgf-m, 159 in-lbf}.
CAUTION:Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE:Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
15. Install the camshaft oil seal retainer and the 2 bolts.
- Tighten in the sequence shown to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
16. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
NOTE:Apply clean engine oil to the seal lip and seal bore before installing the seal.
17. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
- Align the RH camshafts as shown.
18. Install the camshaft bearing caps.
- Loosely install the bolts.
CAUTION:Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled 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 caps can occur.
NOTE:Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
19. Install the camshaft bearing thrust caps.
- Loosely install the bolts.
NOTE:Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
20. Tighten the RH camshaft bearing cap bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
21. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm {1.8 kgf-m, 159 in-lbf}.
CAUTION:Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE:Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
22. Position the oil pump and install the bolts.
- Tighten in the sequence shown to 10 Nm {1.0 kgf-m, 89 in-lbf}.
23. Remove the crankshaft pulley bolt.
24. Install the crankshaft sprockets with the timing marks out.
25. Position the chain tensioner in a soft-jawed vise.
NOTE:LH shown, RH similar.
26. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE:LH shown, RH similar.
27. 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.
28. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
29. If 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.
a. Mark any link to use as the crankshaft timing mark.
b. Starting with the crankshaft timing mark, count 29 links and mark the link.
c. Continue counting to link 42 and mark the link.
30. Install the RH timing chain tensioner arm and the RH timing chain tensioner.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
31. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
a. Install the tensioner arm.
b. Position the tensioner.
i. Install the bolts.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
32. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
33. Verify that the RH camshafts are correctly positioned.
34. Install the RH timing chain and chain guide and install the bolts.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
35. Install the RH timing chain tensioner and tensioner arm.
a. Install the tensioner arm.
b. Position the tensioner.
c. Install the bolts.
i. Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
36. Remove the LH and RH timing chain tensioner piston retaining wires.
37. Rotate the crankshaft counterclockwise 120 degrees to TDC.
38. Verify the timing with the following steps.
a. There should be 12 chain links between the camshaft timing marks.
b. There should be 27 chain links between the camshaft and the crankshaft timing marks.
c. 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.
39. Remove the crankshaft pulley bolt and washer.
40. Install the ignition pulse wheel.
NOTE:This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" only (orange in color).
41. Install the LH and RH spark plugs.
- Tighten to 15 Nm {1.5 kgf-m, 133 in-lbf}.
CAUTION:Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
42. Use a plastic scraping tool to remove all traces of sealant.
- Clean all sealing surfaces with metal surface prep and install new gaskets.
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.
CAUTION:Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
43. 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 surface prep before applying gasket and sealant.
NOTE:The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
44. Position the front cover and install the bolts and stud bolts.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
NOTE:Fasteners 4 and 13 are stud bolts.
45. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Note the position of the alignment dowel on the engine front cover.
Continued in Part 2 Part 2