Installation Procedure
- Piston and Connecting Rod Assembly - Assemble - Piston and Connecting Rod Assemble .
Install the EN-51454 guides into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
- Install the EN-52490 - 74 Piston Ring Compressor or equivalent on the piston.
- Lubricate the pistons, the cylinder bore and the piston ring compressor with engine oil.
- NOTE:
If the old piston and connecting rod will be reused, install in their original position.
Install the 2 pistons (1) with the 2 connecting rods (2), and 2 connecting rod upper bearings (3).
- Raise the vehicle.
- NOTE:
If the old piston and connecting rod will be reused, install in their original position.
Install the 2 connecting rod bearing caps (2) with the 2 connecting rod lower bearings (1).
- Install 4 NEW connecting bearing cap bolts (3). Piston, Connecting Rod, and Bearing Installation
- Rotate the crankshaft 180 degreesto set cylinder 1 to TDC.
- NOTE:
If the old piston and connecting rod will be reused, install in their original position.
Install the 2 pistons (1) with the 2 connecting rods (2), and 2 connecting rod upper bearings (3).
- NOTE:
If the old piston and connecting rod will be reused, install in their original position.
Install the 2 connecting rod bearing caps (2) with the 2 connecting rod lower bearings (1).
- Install 4 NEW connecting bearing cap bolts (3). Piston, Connecting Rod, and Bearing Installation
- Rotate the crankshaft 360 degrees
Crankshaft Pulley Bolt (1) - Remove
- Crankshaft Oil Deflector - Install - Crankshaft Oil Deflector Replacement (With PCV Oil Drain Pipe) , or Crankshaft Oil Deflector Replacement (Without PCV Oil Drain Pipe)
- Oil Pump - Install - Oil Pump Replacement
- Clean the oil pan sealing surface.
Apply a 2.25 mm (0.088 in) bead of sealer (1) around the perimeter of the oil pan. Adhesives, Fluids, Lubricants, and Sealers
Upper Oil Pan (1) - Install - Upper Oil Pan Replacement
Transmission Cover (2) Install
- Transmission Bolt (1) - Install [2x] - Transmission Replacement
Electrical Connector (2) @ Oil Pump Flow Control Solenoid Valve (1) - Connect
Electrical Connector (1) @ Engine Oil Level Indicator Control Module Wiring Harness (2) - Connect
- Use a NEW lower oil pan.
- Clean the oil pan sealing surface.
Apply a 2.25 mm (0, 088 in) bead of sealer (1) around the perimeter of the oil pan. Adhesives, Fluids, Lubricants, and Sealers
Lower Oil Pan (2) - Install - Lower Oil Pan Replacement
- Clean all sealing surfaces.
- Inspect the flatness of cylinder head and the engine block sealing surfaces.
Cylinder Head Gasket (3) - Install - Install a NEW gasket.
- Cylinder Head (1) - Install - Cylinder Head Replacement
EN-36857 Engine Lift Bracket (1) @ Cylinder Head - Install
- EN-51768 Engine Support Fixture Adapter (2) - Install
- Install the engine support fixture hook to the EN-36857 Engine Lift Bracket (1).
Remove the lift hook (3) from the EN-36857 Engine Lift Bracket attached to the engine block.
- Remove the EN-51768 Engine Support Fixture Adapter (2), and EN-36857 Engine Lift Bracket (1) from the engine block.
Timing Chain Guide (1) - Install
- Timing Chain Guide Bolt (2) - Install [3x] - Timing Chain Guide Replacement - Left Side
- NOTE:
Ensure that the actuator timing marks are near the 12 o'clock position.
Timing Chain (1) - Install - Camshaft Timing Chain Replacement
Ensure that the colored link (3) matches to the arrow on the crankshaft sprocket.
- Ensure that the colored links (1, 2) match to the marks on the camshaft position adjuster actuators.
- NOTE:
Both tensioner designs have the same installation procedure.
Install a NEW gasket. (2)
- Timing Chain Tensioner (1) - Install
- Timing Chain Tensioner Bolt (4) - Install [2x] - Timing Chain Tensioner Replacement
Timing Chain Tensioner Shoe (2) - Install
- Timing Chain Tensioner Shoe Bolt (1) - Install - Timing Chain Tensioner Replacement
- Remove the suitable tool from the timing chain tensioner.
Remove the EN-51367 holder (1).
- Timing Chain Upper Guide Replacement - Install
- Check the position of the crankshaft, camshaft and camshaft position actuator adjusters.
Install the EN-51367 holder (1).
- If the EN-51367 holder (1) can be installed, the engine timing is properly adjusted.
- Remove the EN-51367 holder.
- Remove the engine front cover and crankshaft balancer.
- Engine Front Cover - Install - Engine Front Cover Replacement
Engine Mount Bracket (2) - Install
- Engine Mount Bracket Bolt (1) - Install NEW [3x] - Engine Mount Bracket Replacement
Engine Mount Bracket Reinforcement (3) - Install
- Engine Mount Brace Bolt (2) - Install - Engine Mount Bracket Replacement
- Engine Mount Brace Bolt (1) - Install - Engine Mount Bracket Replacement
- Engine Mount - Install - Engine Mount Replacement
Engine Support Fixture (1) - Remove - Engine Support Fixture
Remove the EN-51768 Engine Support Fixture Adapter (2) and EN-36857 Engine Lift Bracket (1).
- Crankshaft Balancer - Install - Crankshaft Balancer Replacement
Upper Oil Pan Bolt (1) - Install [3x] - Upper Oil Pan Replacement
Drive Belt Tensioner (2) - Install
- Drive Belt Tensioner Fastener (1) - Install - Drive Belt Tensioner Replacement
Install the generator. (4)
- Generator Mounting Stud (1) Install - Generator Replacement (LFV)
- Generator Bolt (3) Install [2X] - Generator Replacement (LFV)
- Generator Nut (2) - Install - Generator Replacement (LFV)
Battery Positive Cable (2) - Install
- Battery Positive Cable Nut (3) @ Generator - Install - Generator Replacement (LFV)
- Protective Cap (4) - Install
- Electrical Connector (1) - Connect
- Intake Manifold - Install - Intake Manifold Replacement
Evaporative Emission Front Pipe (3) - Connect
- Evaporative Emission Canister Purge Solenoid Valve Connector (2) - Connect
- Camshaft Cover - Install - Camshaft Cover Replacement
Engine Wiring Harness Bracket (3) - Install
- Electrical Connector (4) @ Exhaust Camshaft Position Sensor (5) - Connect
- Install the heated oxygen sensor wiring harness to the engine wiring harness bracket (3).
- Electrical Connector (8) @ Heated Oxygen Sensor (7) - Connect
- Engine Wiring Harness Bracket Bolt (2) - Install and tighten 9N.m (80 lb in)
- Retainer (1) - Install
Install the NEW vacuum pump gasket (2).
- Install the vacuum pump (1).
Vacuum Pump Bolt (1) - Install [3x] - Vacuum Pump Assembly Replacement
Fuel Injection Fuel Rail Assembly - Install - Fuel Injection Fuel Rail Assembly Replacement
- Fuel Injection Fuel Rail Wiring Harness (1) - Connect
Install the NEW fuel feed intermediate pipe (4).
- Tighten the fuel feed intermediate pipe fittings (2, 5) at the fuel pump (6) and the fuel injection fuel rail (1). Fuel Feed Intermediate Pipe Replacement
- Install the fuel feed intermediate pipe bracket bolt (3). Fuel Feed Intermediate Pipe Replacement
Electrical Connector (2) - Connect
- Fuel Pump Insulator (3) - Install
Engine Wiring Harness Bracket (2) - Install
- Engine Wiring Harness Bracket Bolt (1) - Install [2x] - Fuel Pump Replacement
EN-6015 Closure Plugs - Remove
- Fuel Feed Front Pipe (1) @ Fuel Pump (2) - Connect– Metal Collar Quick Connect Fitting Service
Ignition Coil (2) - Install [4x]
- Ignition Coil Fastener (1) - Install [4x] - Ignition Coil Replacement
Ignition Coil Electrical Connector (1) - Connect [4x]
Install the NEW turbocharger heat shield with gasket (1).
Turbocharger (1) - Install
- Turbocharger Nut (2) - Install NEW [4x] - Compressor Air Intake Turbocharger Replacement
Connect the wiring harness plug (3) to the turbocharger bypass valve solenoid (1).
- Electrical Connector (2) @ Turbocharger Wastegate Regulator Solenoid Valve - Connect
- NOTE:
The PCV hose and fitting assembly connection is permanent. Reinstall these components as an assembly unless new components are being used.
Positive Crankcase Ventilation Tube with Positive Crankcase Ventilation Hose Fitting (2) - Install - Compressor Air Intake Turbocharger Replacement
- Electrical Connector (1) @ Camshaft Position Actuator Solenoid Valve - Disconnect
Turbocharger Coolant Feed Pipe Gasket (2) Install NEW [2x]
- Turbocharger Coolant Feed Pipe Fastener (1) - Install - Turbocharger Coolant Feed Pipe Replacement (LFV)
Turbocharger Coolant Return Pipe (4) - Install - Turbocharger Coolant Return Pipe Replacement (LFV)
Turbocharger Oil Return Pipe Gasket (3) - Install NEW
- Turbocharger Oil Return Pipe (2) @ Turbocharger - Install
- Turbocharger Oil Return Pipe Bolt (1) - Install [2x] - Turbocharger Oil Return Pipe Replacement
Catalytic Converter Clamp (2) - Install
- Catalytic Converter Gasket (1) - Install NEW
- Warm Up Three-Way Catalytic Converter (3) - Install
- Catalytic Converter Brace Bracket Nut (4) - Install [2x] - Warm Up Three-Way Catalytic Converter Replacement (LFV)
Catalytic Converter Brace Bracket (3) - Install
- Catalytic Converter Brace Bracket Nut (2) - Install - Catalytic Converter Brace Bracket Replacement (Lower LFV) , or Catalytic Converter Brace Bracket Replacement (Upper LFV)
- Exhaust Front Pipe - Install - Exhaust Front Pipe Replacement (LFV)
Catalytic Converter Clamp Bolt (1) - Tighten - Warm Up Three-Way Catalytic Converter Replacement (LFV)
Catalytic Converter Brace Bracket Nut (1) - Install [2x] - Warm Up Three-Way Catalytic Converter Replacement (LFV)
Charge Air Cooler Inlet Hose (2) @ Turbocharger (2) - Install
- Charge Air Cooler Inlet Hose Quick Connector (1) - Engage
Charge Air Cooler Inlet Hose (2) @ Charge Air Cooler - Install
- Charge Air Cooler Inlet Hose Quick Connector (1) - Engage
- Front Compartment Splash Shield - Install - Front Compartment Splash Shield Replacement
Turbocharger Heat Shield Fastener (1) - Install [6x] - Turbocharger Heat Shield Replacement
- Turbocharger Heat Shield (2) - Install
Heated Oxygen Sensor Electrical Connector - Connect
Water Pump and Air Conditioning Compressor and Generator Belt (2) - Install - Water Pump, Air Conditioning Compressor, and Generator Belt Replacement
Heater Coolant Pump Hose (2) - Reposition
- Heater Outlet Hose Bracket Bolt (1) - Install
Thermostat Bypass Pipe Bolt (1) - Install - Thermostat Bypass Pipe Replacement (LFV)
Heater Inlet Hose (4) @ Water Outlet (1) - Install
- Heater Outlet Hose (3) @ Water Outlet (1) - Install
- Radiator Outlet Hose (5) @ Water Outlet (1) - Install
- Thermostat Bypass Hose (7) @ Water Outlet (1) - Install
- Clamp (2, 6) - Install [4x] - Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Temperature Sensor Electrical Connector (3) - Connect
- Ground Cable (2) - Reposition
- Engine Wiring Harness Ground Bolt (1) - Install and tighten 11N.m (97 lb in)
Engine Coolant Air Bleed Hose (2) @ Water Outlet - Connect
Engine Coolant Air Bleed Hose (2) @ Turbocharger Coolant Return Pipe - Connect - Engine Coolant Air Bleed Hose Replacement (Turbocharger Coolant Return Pipe to Water Outlet, LFV) , or Engine Coolant Air Bleed Hose Replacement (Turbocharger Coolant Return Pipe to Radiator Surge Tank, LFV)
Power Brake Booster Vacuum Pipe Fitting (1) @ Vacuum Pump - Connect
- Charge Air Cooler Outlet Air Tube - Install - Charge Air Cooler Outlet Air Tube Replacement
Intake Manifold Insulator (4) - Install
- Intake Manifold Cover (3) - Install
- Intake Manifold Cover Fastener (2) - Install - Intake Manifold Cover Replacement
- Oil Cap (1) - Install
Air Cleaner Assembly (1) - Install - Air Cleaner Assembly Replacement
Air Cleaner Outlet Duct (2) - Install - Air Cleaner Outlet Duct Replacement
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (Without KL9) , or Battery Negative Cable Disconnection and Connection (With KL9)
- Fill the cooling system. - Cooling System Draining and Filling (GE-47716) , or Cooling System Draining and Filling (Static)
- Check and correct the engine oil level. Engine Oil and Oil Filter Replacement
The lower crankcase and oil pan mating surfaces must be free of contamination prior to applying the sealer.
Install and align the oil pan to block within 20 minutes of applying the sealer.
The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer.
The complete installation procedure of the lower oil pan should be completed within 20 minutes.
Ensure that the cylinder head and engine block sealing surfaces are clear of oil, grease and old gasket material.
Refer to Fastener Caution .
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.