Part 2
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ENGINE ASSEMBLY - HYBRID
Part 2
Continued From Part 1 Part 1
41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE:Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE:If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
42. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
a. Remove any large deposits of silicone or gasket material with a plastic scraper.
b. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
c. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
d. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
43. Apply silicone gasket and sealant to the locations shown.
44. Install a new head gasket.
NOTE:The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
45. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages.
- Stage 1: Tighten the bolts to 5 Nm {0.5 kgf-m, 44 in-lbf}.
- Stage 2: Tighten the bolts to 15 Nm {1.5 kgf-m, 132 in-lbf}.
- Stage 3: Tighten the bolts to 45 Nm {4.6 kgf-m, 33 ft-lbf}.
- Stage 4: Turn the bolts 90 degrees.
- Stage 5: Turn the bolts an additional 90 degrees.
NOTE:Coat the valve tappets with clean engine oil prior to installation.
46. Install the valve tappets.
CAUTION:Install the camshafts with the alignment slots in the camshafts 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 when the timing chain is removed, 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.
47. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages.
- Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until finger-tight.
- Stage 2: Tighten the bolts to 7 Nm {0.7 kgf-m, 62 in-lbf}.
- Stage 3: Tighten the bolts to 16 Nm {1.6 kgf-m, 142 in-lbf}.
48. Install the VCT system oil filter and the plug in the intake camshaft thrust cap.
- Tighten the bolts to 17 Nm {1.7 kgf-m, 150 in-lbf}.
49. Install the Variable Camshaft Timing (VCT) solenoid and the bolt.
- Tighten the bolts to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
50. Install a new crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
- The crankshaft sprocket flange must be facing away from the engine block.
51. Install the oil pump chain, sprocket and bolt.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
52. Install the shoulder bolt.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
53. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
CAUTION:The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
54. Install the special tool in the slots on the rear of both camshafts.
55. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
56. Install the LH timing chain guide and the bolts.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
57. Install the timing chain.
NOTE:If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
58. Install the RH timing chain guide.
CAUTION:Do not compress the ratchet assembly. This will damage the ratchet assembly.
59. Using the edge of a vise, compress the timing chain tensioner plunger.
60. Using a small pick, push back and hold the ratchet mechanism.
61. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
62. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
63. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
CAUTION:The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
64. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
- Tighten to 72 Nm {7.3 kgf-m, 53 ft-lbf}.
CAUTION:Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
65. Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE:The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
66. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
67. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
- Tighten the 8 mm bolts to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Tighten the 13 mm bolts to 48 Nm {4.9 kgf-m, 35 ft-lbf}.
NOTE:Remove the throughbolt from the special tool.
NOTE:Lubricate the oil seal with clean engine oil.
68. Using the special tool, install a new crankshaft front oil seal.
CAUTION:Do not install the crankshaft pulley bolt at this time.
NOTE:Apply clean engine oil on the seal area before installing.
69. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
CAUTION:Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
NOTE:This step will correctly align the crankshaft pulley to the crankshaft.
70. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
CAUTION:The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
CAUTION:Do not reuse the crankshaft pulley bolt.
71. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm {10.2 kgf-m, 74 ft-lbf}.
- Stage 2: Tighten an additional 90 degrees (one-quarter turn).
72. Remove the 6 mm x 18 mm bolt.
73. Remove the Crankshaft TDC Timing Peg.
74. Remove the Camshaft Alignment Plate.
NOTE:Only turn the engine in the normal direction of rotation.
75. Turn the crankshaft clockwise one and three-quarters turn.
Continued in Part 3 Part 3