Installation Procedure
- Remove the M10-1.5 x 120mm (3) and the M10-1.5 x 45mm (2) bolts.
- Remove the EN-42386 Flywheel Holding Tool (1).
- Crankshaft Sprocket (1) @Crankshaft - Install
- Rotate the crankshaft sprocket until the sprocket alignment mark (1) is in the 12 o'clock position.
- Timing Chain Tensioner (1) - Install
- Timing Chain Tensioner Bolt (2) - Install and hand tighten
- Remove and DISCARD the tie strap from the actuator.
- The camshaft sprocket alignment mark (1) and the crankshaft sprocket alignment mark (2) must be aligned properly.NOTE:
The alignment mark on the camshaft position actuator (2) and the alignment mark on the crankshaft sprocket (1) are off-center from the oil pump feed hole gasket on the timing chain tensioner. The alignment marks need to be lined up with one another, but NOT with the oil feed hole.
- If the alignment marks on the camshaft position actuator (1) and crankshaft sprocket (2) are difficult to see or line up, an alternate method can be used. Mark the gear tooth directly opposite of the alignment mark on the camshaft position actuator. Mark the gear tooth directly opposite of the alignment mark on the crankshaft sprocket.
- The timing chain has 30 links. Place links (1) and (30) on either side of the mark made on the camshaft position actuator and place links (15) and (16) on either side of the mark made on the crankshaft sprocket. This will ensure that the factory alignment marks are in the correct position and that the engine is properly timed.
- Identify the alignment hole (1) in the rear face of the camshaft position actuator and the locating pin (2) on the front face of the camshaft.NOTE:
- Properly locate the camshaft position actuator (1) onto the locating pin of the camshaft (2).
- The sprocket teeth and timing chain must mesh.
- The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
- Do not use the camshaft position solenoid valve again. Install a NEW valve during assembly.
- Install the camshaft position actuator (3) and timing chain (1). Align the hole in the rear face of the camshaft position actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets (2) in order to align the timing marks. Use care to install the actuator (3) completely onto the front of the camshaft. Position fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator.WARNING:
Refer to Camshaft Position Actuator Removal and Installation Warning .
- Position fingers onto the face of the actuator sprocket (2) and push the actuator onto the front of the camshaft.
- Position the EN-42386
Flywheel Holding Tool (1) into place.
- Install the M10-1.5 x 120mm (3) and the M10-1.5 x 45mm (2) bolts and tighten to 50 N.m (37 lb ft).
- Camshaft Position Actuator Solenoid Valve (1) - Install NEW and tighten - Fastener SpecificationsCAUTION:
Refer to Torque-to-Yield Fastener Caution
CAUTION:Refer to Component Fastener Tightening Caution .
- Locate a straight edge (1) across the front face of the engine block (2) and inspect for proper installation of the camshaft position actuator and timing chain (3). With the camshaft position actuator properly and completely installed onto the front of camshaft, the timing chain (3) will not protrude beyond the front face of engine block (2).NOTE:
It is possible to push the camshaft rearward when installing the camshaft position actuator solenoid valve. Verify that the camshaft lobes are centered in the valve lifter bores after the camshaft position actuator is installed.
- Inspect the sprockets for proper alignment. The mark on the camshaft position actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position.
- Timing Chain Tensioner Bolt (1) - Install and hand tighten
- Timing Chain Tensioner Bolt (1) - Tighten [2x] - Fastener SpecificationsCAUTION:
Refer to Fastener Caution .
- Remove the EN-46330
Timing Belt Tensioner Retaining Pin (1) from the timing chain tensioner (2).
- Oil Pump (1) - Install
- Oil Pump Bolt (1) - Install and hand tighten [4x]
- Oil Pump Bolt (1) - Tighten in sequence [4x] - Fastener Specifications
- Apply a 3 mm (0.118 in) bead of RTV sealant on the engine front cover (1). Adhesives, Fluids, Lubricants, and SealersNOTE:
- Install and align the front cover within 10 minutes of applying the sealer.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a 5 mm (0.197 in) bead of RTV sealant on the engine front cover (2). Adhesives, Fluids, Lubricants, and Sealers
- Engine Front Cover (2) - Install
- Engine Front Cover Bolt (1, 3) - Install and hand tighten [10x]
- Engine Front Cover Bolt (1, 3) - Tighten in sequence [10x] - Fastener Specifications
- If the engine front cover is reused, perform the following steps:NOTE:
If the engine front cover is reused, the crankshaft front oil seal (3) must be replaced.
- For proper orientation, note the installation direction of the crankshaft front oil seal (3). The crankshaft front oil seal is a reverse-lip design. Install with "THIS SIDE OUT" displayed as shown.
- Do NOT lubricate the crankshaft front oil seal sealing surface.
- Install the crankshaft front oil seal (3) with "THIS SIDE OUT" facing away from the engine.
- Install the NEW crankshaft front oil seal (3) to the EN-51091 Crankshaft Front Oil Seal Installer (2).
- Install the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) into the crankshaft.
- Rotate the EN-51091 Crankshaft Front Oil Seal Installer (2) clockwise until the NEW crankshaft front oil seal (3) enters the engine front cover and seats into the bottom of the engine front cover.
- Remove the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) from the crankshaft and engine front cover.
- Inspect the crankshaft front oil seal (3) for proper installation. The crankshaft front oil seal should be installed evenly and completely into the engine front cover.
NOTE: - Water Pump Gasket (2) - Install NEW [2x]
- Water Pump (1) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Water Pump Housing Bolt (1) - Install and hand tighten [6x]
- Water Pump Housing Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
- Engine Coolant Temperature Sensor Electrical Connector (1) - Connect
- Radiator Inlet Hose (3) @Water Pump - Install
- Engine Coolant Air Bleed Hose (2) @Water Pump - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @Water Pump - Install
- Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Water Auxiliary Pump Hose (3) @Water Pump - Install
- Heater Inlet Hose (2) @Water Pump - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Air Conditioning Compressor (1) - Install
- Air Conditioning Compressor Bolt (1) - Loosely install
- Air Conditioning Compressor Stud (3) - Install and tighten - Fastener Specifications
- Air Conditioning Compressor Bolt (1) - Tighten - Fastener Specifications
- Air Conditioning Compressor Nut (2) - Install and tighten - Fastener Specifications
- Generator (1) - Install
- Generator Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Engine Cooler Fan (1) @Engine Radiator - Install
- Engine Coolant Fan Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Transmission Fluid Cooler Pipe Clip (1) - Secure
- Transmission Fluid Cooler Pipe Clip (2) - Install [2x]
- Transmission Fluid Cooler Pipe Bolt (1) - Install and tighten - Fastener Specifications
- Engine Oil Cooler Hose (1) @Engine Radiator - Install [2x]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Install and tighten - Fastener Specifications
- Engine Oil Cooler Retainer (2) - Install [2x]
- Engine Oil Cooler Hose Clip (1) - Secure
- Position the wiring harness. (3)
- Electrical Connector (1) - Connect
- Wiring Harness Retainer (2) - Install [2x]
- Position the wiring harness. (2)
- Electrical Connector (3) - Connect
- Wiring Harness Retainer (1) - Install [2x]
- Radiator Inlet Hose (3) @Engine Radiator - Install
- Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose Clip (2) - Install
- Radiator Surge Tank Outlet Hose (3) - Move into position
- Radiator Surge Tank Outlet Hose Clip (2) - Install [2x]
- Apply a 3 mm (0.118 in) bead of RTV sealant on the oil pan (1). Adhesives, Fluids, Lubricants, and Sealers
- Apply a 5 mm (0.197 in) bead of RTV sealant on the oil pan (2). Adhesives, Fluids, Lubricants, and Sealers
- Oil Pan High Pressure Port Seal (2) - Install NEW [2x]
- Oil Pan Front Seal (3) - Install NEW
- Oil Pan (1) - Install
- Oil Pan Bolt (2, 3) - Install and hand tighten [16x]
- Oil Pan Bolt (2, 3) - Tighten in sequence [16x] - Fastener Specifications
- Electrical Connector (1) - Connect
- Crankshaft Balancer (1) - Loosely install
- Install the EN-41478-A
Crankshaft Front Oil Seal Installer (3) and the EN-41665-A
Crankshaft Balancer and Sprocket Installer (2) to the crankshaft.
- Using the EN-41665-A Crankshaft Balancer and Sprocket Installer (2) properly seat the crankshaft balancer (1).
- Remove the EN-41478-A Crankshaft Front Oil Seal Installer (3) and the EN-41665-A Crankshaft Balancer and Sprocket Installer (2).
- Crankshaft Balancer Bolt (1) - Install NEW and tighten - Fastener SpecificationsCAUTION:
Refer to Torque-to-Yield Fastener Caution
- Engine Wiring Harness (3) - Install
- Engine Wiring Harness Retainer (2) - Install
- Engine Wiring Harness Ground Stud (1) - Install and tighten [2x] - Ground Repair
- Install and tighten the transmission fluid auxiliary cooler pipe bracket nut (1). Fastener Specifications
- Transmission Fluid Cooler Pipe Clip Bracket (2) @Oil Pan - InstallNOTE:
Components removed in graphic to better illustrate service parts.
- Transmission Fluid Cooler Pipe Clip Bolt (1) @Oil Pan - Install and tighten - Fastener Specifications
- Electrical Connector@Knock Sensor (4) - Connect
- Oil Filter (1) - Install and tighten - Fastener Specifications
- Transmission Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Engine Oil Cooler Gasket (2) - Install NEW
- Engine Oil Cooler Hose (1) @Oil Pan - Install
- Engine Oil Cooler Adapter Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Electrical Connector (1) @Engine Oil Pressure Sensor - Connect
- Wiring Harness Retainer (2) @Engine Oil Cooler Hose - Install
- Engine Oil Pressure Sensor Sleeve (1) - Install
- Engine Oil Cooler Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
- Lubricate the oil level indicator seal (2) with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Oil Level Indicator Seal (2) - Install NEW
- Oil Level Indicator Tube (1) @Oil Pan - Install
- Connect the wiring harness connectors (3) and retainers as needed.
- Engine Wiring Harness Retainer (1) @Oil Level Indicator Tube (2) - Connect
- Remove the M10-1.5 x 120mm (3) and the M10-1.5 x 45mm (2) bolts.
- Remove the EN-42386 Flywheel Holding Tool (2)
- Torque Converter Cover- Right Side (2) - Install
- Torque Converter Cover Bolt- Right Side (1) - Install and tighten - Fastener Specifications
- Torque Converter Cover- Left Side (2) - Install
- Torque Converter Cover Bolt- Left Side (1) - Install and tighten - Fastener Specifications
- Starter (1) - Install
- Electrical Connector (3) - Connect
- Protective Sleeve (4) - Install
- Starter Solenoid Cable (1) - Install
- Starter Solenoid Cable Nut (2) - Install and tighten - Fastener Specifications
- Starter Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Starter Solenoid Cable (2) - Install
- Battery Negative Cable Ground Bolt (1) - Install and tighten - Fastener Specifications
- Starter Heat Shield (2) - Install
- Starter Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
- Starter Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Drivetrain and Front Suspension Frame Front Crossmember (1) - Install
- Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Install [4x]
- Drivetrain and Front Suspension Frame Reinforcement Nut (1) - Install and tighten [4x] - Fastener Specifications
- Install the heater coolant pump and heater water auxiliary pump bracket (2) as assembly.NOTE:
Some components not shown for graphic clarity.
- Heater Water Auxiliary Pump Bolt (1) - Install and tighten - Fastener Specifications
- Electrical Connector@Heater Coolant Pump (2) - ConnectNOTE:
Support the front stabilizer shaft.
- Front Stabilizer Shaft (3) - Install
- Front Stabilizer Shaft Clamp (2) - Install [2x]
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Stabilizer Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Fuse Block Bracket (3) - Install
- Retaining Tab (1) - Engage
- Engine Wiring Harness Fuse Block Bracket Bolt (2) - Tighten [2x] - Fastener Specifications
- Electrical Connector (1) - Install [4x]
- Engine Wiring Harness Junction Block (3) - Install
- Retaining Tab (1) - Engage [4x]
- Engine Wiring Harness Junction Block Bolt (2) - Tighten [4x] - Fastener Specifications
- Starter Solenoid Cable (4) - Install
- Battery Positive Cable Nut (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Junction Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
- Starter Solenoid Cable (2) - Install
- Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications
- Electrical Connector (3) - Connect
- Install the accessory drive auxiliary belt (1) following the instructions included with the accessory drive auxiliary belt.NOTE:
The OEM replacement stretchy accessory drive auxiliary belt (1) is packaged with a disposable installation tool and installation instructions.
- Inspect the accessory drive auxiliary belt (1) for proper installation and alignment.
- Rotate the crankshaft balancer (1) an additional 360 degrees to ensure proper accessory drive auxiliary belt installation.
- Position the accessory drive primary belt (4) on the belt idler pulley (2), fan and water pump pulley (3) and generator (1).
- Install the EN-51767-2
Stretchy Belt Installer (1) onto the crankshaft balancer.
- Position the accessory drive primary belt (2) on the crankshaft balancer.
- Slowly rotate the crankshaft balancer in a clockwise direction until the accessory drive primary belt (2) fully seats on the crankshaft balancer.
- Remove the EN-51767-2 Stretchy Belt Installer (1) from the crankshaft balancer.
- Inspect the accessory drive primary belt (1) for proper installation and alignment.
- Rotate the crankshaft balancer (1) and additional 360 degrees to ensure proper accessory drive primary belt installation.
- Air Cleaner Outlet Duct (3) - Install
- Air Cleaner Outlet Duct Clamp (2) - Tighten [2x] - Fastener Specifications
- Positive Crankcase Ventilation Fresh Air Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Install engine wiring harness to air cleaner outlet duct bracket.
- Underbody Skid Shield (3) - Install
- Underbody Splash Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Underbody Splash Shield (1) - Install
- Underbody Splash Shield Bolt (1) - Install and tighten [4x]
- Underbody Splash Shield Bolt (2) - Install and tighten [4x] - Fastener Specifications
- Lower the vehicle.
- Fill the engine oil to the proper level with NEW engine oil.
- Install the oil level indicator. (1)
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Fill the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Start the engine and check for coolant leaks.
- Check for oil leaks.
NOTE:
Never push on the reluctor wheel when attempting to install the actuator.