Part 2

Engine















Engine - Upper End















Engine - Lower End

















NOTICE: 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, can cause engine failure.

NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Engine System - General Information Specifications.


31. Position the oil pan baffle and gasket.





32. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt.

Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts in 2 stages.

- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.





33. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).





34. NOTE: Fastener location 7 is a stud bolt.

Install the oil pan and tighten the fasteners in sequence in 3 stages.

- Stage 1: Tighten to 2 Nm (18 lb-in)

- Stage 2: Tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten an additional 45 degrees.





35. NOTE: Install a new oil filter adapter gasket.

Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten the bolts in 2 stages.

- Stage 1: Tighten the bolts to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 60 degrees.





36. NOTE: Do not lubricate the O-ring seal.

Install a new oil filter.

- Tighten to 16 Nm (142 lb-in).

37. NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.

Position the CKP sensor and install the bolt.

- Tighten to 10 Nm (89 lb-in).





38. Install the 2 Knock Sensor (KS) and 2 bolts.
- Tighten to 20 Nm (177 lb-in).





39. Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the flange facing forward.





40. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.

NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.





41. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 40 Nm (30 lb-ft).

- Stage 3: Tighten an additional 90 degrees.

- Stage 4: Tighten an additional 90 degrees.





42. NOTICE: 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 scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

43. Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).





44. NOTE: The tightening specification differs between early build (coarse thread) and late build (fine thread) exhaust manifold nuts.

Install new gaskets, the RH exhaust manifold and 8 new nuts.

- Tighten early build (coarse thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 28 Nm (21 lb-ft).

- Stage 2: Tighten to 37 Nm (27 lb-ft).

- Tighten late build (fine thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).





45. Install the Cylinder Head Temperature (CHT) sensor.
- Tighten to 11 Nm (97 lb-in).





46. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.

Using a new O-ring seal, install the coolant outlet pipe.

- Tighten to 10 Nm (89 lb-in).





47. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 40 Nm (30 lb-ft).

- Stage 3: Tighten an additional 90 degrees.

- Stage 4: Tighten an additional 90 degrees.





48. NOTICE: 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 scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

49. Install 8 new LH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).





50. NOTE: The tightening specification differs between early build (coarse thread) and late build (fine thread) exhaust manifold nuts.

Install new gaskets, the LH exhaust manifold and 8 new nuts.

- Tighten early build (coarse thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 28 Nm (21 lb-ft).

- Stage 2: Tighten to 37 Nm (27 lb-ft).

- Tighten late build (fine thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).





51. Using a new gasket, install the coolant outlet and 2 bolts.
- Tighten to 10 Nm (89 lb-in).





52. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.

Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.





53. NOTE: Lubricate the camshafts with clean engine oil prior to installation.

Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.





54. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.

55. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time





56. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).

- Stage 2: Tighten an additional 45 degrees.





57. NOTE: Intake camshaft shown, exhaust camshaft similar.

Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.





58. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.

1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.

2. The timing mark on the exhaust VCT assembly should align with the single colored link.





59. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11 o'clock position.





60. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.

- If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.