Installation Procedure
- To install individual components, carry out only the listed steps.INDIVIDUAL COMPONENTS REMOVING STEPS
Component Steps LH cylinder head 1-3, 15-65, 72-147 RH cylinder head 4-14, 23-59, 66-147 - Illustration 1 of 20. Install the components in the order indicated in the following illustration and table. See Fig 1.
- Illustration 2 of 20. Install the components in the order indicated in the following illustration and table. See Fig 2.
- Illustration 3 of 20. Install the components in the order indicated in the following illustration and table. See Fig 3.
- Illustration 4 of 20. Install the components in the order indicated in the following illustration and table. See Fig 4.
- Illustration 5 of 20. Install the components in the order indicated in the following illustration and table. See Fig 5.
- Illustration 6 of 20. Install the components in the order indicated in the following illustration and table. See Fig 6.
- Illustration 7 of 20. Install the components in the order indicated in the following illustration and table. See Fig 7.
- Illustration 8 of 20. Install the components in the order indicated in the following illustration and table. See Fig 8.
- Illustration 9 of 20. Install the components in the order indicated in the following illustration and table. See Fig 9.
- Illustration 10 of 20. Install the components in the order indicated in the following illustration and table. See Fig 10.
- Illustration 11 of 20. Install the components in the order indicated in the following illustration and table. See Fig 11.
- Illustration 12 of 20. Install the components in the order indicated in the following illustration and table. See Fig 12.
- Illustration 13 of 20. Install the components in the order indicated in the following illustration and table. See Fig 13.
- Illustration 14 of 20. Install the components in the order indicated in the following illustration and table. See Fig 14.
- Illustration 15 of 20. Install the components in the order indicated in the following illustration and table. See Fig 15.
- Illustration 16 of 20. Install the components in the order indicated in the following illustration and table. See Fig 16.
- Illustration 17 of 20. Install the components in the order indicated in the following illustration and table. See Fig 17.
- Illustration 18 of 20. Install the components in the order indicated in the following illustration and table. See Fig 18.
- Illustration 19 of 20. Install the components in the order indicated in the following illustration and table. See Fig 19.
- Illustration 20 of 20. Install the components in the order indicated in the following illustration and table. See Fig 20.
- Remove the engine from the engine stand.
- Install the engine. For additional information, refer to ENGINE under INSTALLATION in this section.
Items 1-6: RH and LH Cylinder Head Installation Note
- Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
- Position the cylinder heads.
- Install new gaskets.
- Install and tighten the RH head bolts in four stages in the sequence shown. See Fig 22.
- Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
- Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
- Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
- Install and tighten the bolts in two stages.
- Tighten to 20 N.m (15 lb-ft).
- Tighten an additional 90 degrees.
- Install and tighten the LH head bolts in four stages in the sequence shown. See Fig 24.
- Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
- Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
- Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
- Install and tighten the bolts in two stages.
- Tighten to 20 N.m (15 lb-ft).
- Tighten an additional 90 degrees.
Items 7-22: RH and LH Camshaft Installation Note
- Position the camshafts on the camshaft journals.
- Install the RH camshaft bearing caps.
- Position the bearing caps.
- Install the bolts. Tighten the bolts in three stages in the sequence shown. See Fig 27.
- Stage 1: Hand-tighten.
- Stage 2: Tighten to 6 N.m (53 lb-in).
- Stage 3: Tighten an additional 90 degrees.
- Install the LH camshaft bearing caps.
- Position the bearing caps.
- Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. See Fig 28.
- Stage 1: Hand-tighten.
- Stage 2: Tighten to 6 N.m (53 lb-in).
- Stage 3: Tighten an additional 90 degrees.
- Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to VALVE CLEARANCE CHECK in this section.
- If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to VALVE CLEARANCE ADJUSTMENT in this section.
Items 24-30, : LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note
- Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
- Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
- Remove the locking pin from the LH secondary timing chain tensioner.
Items 31-37: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note
- Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
- Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
- Remove the locking pin from the RH secondary timing chain tensioner.
Items 38-51: Timing Drive Components Installation Note
- Reset the timing chain tensioners.
- Hold the lever toward the tensioner piston.
- Using finger pressure, compress the tensioner.
- Push the lever down and install a drill rod to lock the piston.
- Install the special tool on the LH head.
- Position the LH timing chain and crankshaft gear.
- Position the timing chain over the LH intake camshaft sprocket.
- Position the crankshaft gear in the timing chain.
- Install the LH timing chain guide.
- Install the LH timing chain tensioner arm.
- Install the LH timing chain tensioner.
- Install the timing chain tensioner and bolts.
- Remove the drill rod.
- Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages:
- Stage 1: Tighten to 35 N.m (26 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Remove the special tool.
- Install the special tool on the right cylinder head.
- Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
- Install the RH timing chain guide.
- Install the RH timing chain tensioner arm.
- Install the RH timing chain tensioner.
- Install the timing chain tensioner and bolts.
- Remove the drill rod.
- Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages:
- Stage 1: Tighten to 35 N.m (26 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Remove the special tool.
- Remove the special tool.
- Install the crankshaft position (CKP) sensor.
Items 52 and 55: Variable Cam Timing (VCT) Bush Carrier Installation Note
- Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.
Items 58 and 59: Engine Front Cover Installation Note
- Apply silicone gasket and sealant in eight places.
- Install the engine front cover.
- Install new gaskets.
- Position the engine front cover on the cylinder block.
- Loosely install the bolts.
- Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 5 N.m (44 lb-in).
- Stage 2: Tighten to 10 N.m (89 lb-in).
Items 61-62 and 67-68: Exhaust Manifold Installation Note
- Install the exhaust manifold.
- Install a new gasket and the exhaust manifold.
- Tighten the eight nuts in the sequence shown.
Item 67: RH Exhaust Manifold Installation Note
- Install the EGR tube.
- Install a new EGR tube gasket.
- Install the EGR tube.
- Install the EGR tube nuts.
Items 72-79: RH and LH Valve Cover Installation Note
- Inspect and install new gaskets as necessary.
- Apply four beads of silicone gasket and sealant as shown. See Fig 58.
- Install the valve covers.
- Tighten the bolts in the sequence shown.
Items 81-83: Intake Manifold Installation Note
- Install new intake manifold gaskets.
- Install the intake manifold and tighten the bolts in the sequence shown.
- Install the radio interference capacitor and the nut.
Item 96: EGR System Module Installation Note
- Connect the EGR system module-to-exhaust manifold tube from the EGR system module.
Item 103: Engine Wiring Harness Installation Note
- Install the wiring harness onto the front cover.
- Install the wiring harness onto the front cover.
- Connect the crankshaft position (CKP) sensor electrical connector.
- Install the exhaust gas oxygen sensor (HO2S) connectors onto the brackets.
- Connect the two pin-type retainers.
- Connect the variable cam timing (VCT) sensor electrical connector.
- Install the engine wiring harness retainer.
- Connect the fuel injector and radio interference capacitor electrical connectors.
- Connect the ignition coil electrical connectors.
- Connect the EGR system module electrical connector.
- Connect the generator electrical connector.
- Connect the engine wiring harness retainers to the RH engine appearance cover support bracket.
Items 106 and 107: Engine Cover Support Bracket Installation Note
- Install the engine wiring harness retainers onto the engine cover support bracket.
Item 109: Oil Level Indicator Tube Installation Note
- Install a new O-ring seal and the oil level indicator tube.
- Lubricate the new O-ring seal and engine mating surface with clean engine oil.
Items 122-125: RH and LH Coil Cover Installation Note
- Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
- Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.
- Install the coil cover.
- Connect the wiring harness retainers to the RH valve cover.
- Connect the wiring harness retainers to the RH valve cover.
Item 129: Front Crankshaft Seal Installation Note
- Using the special tool, install the front crankshaft seal.
Items 130-132: Crankshaft Pulley Installation Note
- Apply silicone gasket and sealant to the crankshaft pulley keyway.
- Using the special tool, install the crankshaft pulley.
- Install the washer and a new bolt and tighten in two stages.
- Stage 1: Tighten to 80 N.m (59 lb-ft).
- Stage 2: Tighten an additional 80 degrees.
Item 134: Coolant Pump Pulley Bolt Installation Note
- Do not tighten coolant pump pulley bolts until after the accessory drive belt has been installed.
Items 144 and 145: Oil Filter and Seal Installation Note
- Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.