Part 2

Engine














Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










Lower Engine Block (View 1)










Lower Engine Block (View 2)









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, may cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

All engines

41. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).






42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 45 degrees.






43. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).






44. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.






45. NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Install the valve tappets.






46. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.






47. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

- Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).

- Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 4: Loosen bolts 5 and 6.
- Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).

- Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 8: Loosen bolts 13 and 14.
- Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.





48. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH cylinder head in the neutral position as shown.






49. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

- Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).

- Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 4: Loosen bolts 5 and 6.
- Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).

- Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 8: Loosen bolts 13 and 14.
- Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.





50. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to Valve Clearance Check Adjustments.





51. Install the RH timing chain guide and bolt.
- Tighten to 10 Nm (89 lb-in).






52. Install the RH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






53. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.






54. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.






55. Position the RH secondary timing assembly onto the camshafts.





56. Install the new VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






57. Remove the lockpin from the RH secondary timing chain tensioner.





58. Install the LH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






59. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the LH camshafts to the TDC (Top Dead Center) position and install the Camshaft Holding Tool on the flats of the camshafts.






60. Assemble the LH VCT (Variable Camshaft Timing) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
- Align the colored links with the timing marks.






61. Position the LH secondary timing assembly onto the camshafts.





62. Install the new VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






63. Remove the lockpin from the LH secondary timing chain tensioner.





64. Rotate the crankshaft clockwise 60 degrees to the TDC (Top Dead Center) position (crankshaft dowel pin at 11 o'clock).





65. Install the crankshaft timing chain sprocket.





66. Install the upper LH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).






67. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

Install the primary timing chain with the colored links aligned with the timing marks on the VCT (Variable Camshaft Timing) assemblies and the crankshaft sprocket.






68. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






69. Install the primary timing chain tensioner arm.





70. Reset the primary timing chain tensioner.
1. Release the ratchet detent.

2. Using a soft-jawed vise, compress the ratchet plunger.

3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.