Part 2

Engine


























Assembly (Steps 31-60)

31. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.





32. Install the crankshaft sprocket, making sure the flange faces forward.





33. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.





34. Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position.





35. CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body, or permanent compression of the seal bead, will require installation of a new tensioner. Failure to follow this instruction may result in damage to the engine.

Inspect the RH and LH timing chain tensioners.
^ Install new tensioners as necessary.

36. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

Compress the tensioner plunger, using a vise.





37. Install a retaining clip on the tensioner to hold the plunger in during installation.





38. Remove the tensioner from the vise.
39. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.





40. Install the 4 bolts and the LH and RH timing chain guides.
^ Tighten to 10 Nm (89 lb-in).





41. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.





42. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.





43. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).





44. Remove the retaining clip from the LH timing chain tensioner.





45. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.





46. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.





47. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).





48. Remove the retaining clip from the RH timing chain tensioner.





49. NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.

As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.





50. Install the crankshaft sensor ring on the crankshaft.





51. NOTE: Lubricate the roller followers with clean engine oil prior to installation.

Using the special tool, install all of the camshaft roller followers.





52. 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 old sealant.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.





53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.





54. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).








55. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.





56. Using the special tools, install the crankshaft front oil seal into the engine front cover.





57. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.





58. Using the special tool, install the crankshaft pulley.





59. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.

60. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

Position the coolant pump and install the 4 bolts loosely.