Part 1
Engine
Assembly
1. CAUTION: Use only a plastic scraper when removing old gasket material.
Clean all the mating faces and reusable parts thoroughly and check for damage.
^ If gasket material remains on the cylinder head after cleaning, use a plastic tipped scraper to remove remaining material.
2. NOTE: Never remove pipe plugs or alignment dowels unless they are to be serviced.
Reseal oil passage blanking plugs, as necessary.
3. NOTE: The main bearings are precision selective fit.
NOTE: Lubricate the upper crankshaft main bearings and thrust washers.
Install the upper crankshaft main bearings.
1. Install the upper crankshaft thrust washers.
2. Install the upper crankshaft main bearings.
4. CAUTION: Avoid damage to any crankshaft bearing surfaces.
Install the crankshaft.
5. NOTE: The main bearings are precision selective fit.
NOTE: Install lower cylinder block and tighten bolts to specification within twenty minutes of applying sealer.
Apply a bead of sealant to the cylinder block housing.
^ Use WSS-M4G320-A3-RTV sealant.
6. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to tightening the bolts.
CAUTION: Do not lubricate the lower cylinder block bolts.
CAUTION: Do not rotate crankshaft until all bolts are tightened to specification.
CAUTION: Bolts must be tightened within twenty minutes of applying sealer.
CAUTION: Tighten the bolts in the sequence shown.
Install the lower cylinder block to the upper cylinder block.
3. Tighten bolts 21 to 32 to 15 Nm
4. Tighten bolts 33 to 34 to 15 Nm
5. Tighten bolts 1 to 10 to 25 Nm
6. Tighten bolts 11 to 20 to 15 Nm
7. Tighten bolts 1 to 10 to 35 Nm + 135°
8. Tighten bolts 11 to 20 to 20 Nm + 150°
9. Tighten bolts 21 to 32 to 20 Nm + 90°
10. Tighten bolts 33 to 34 to 20 Nm + 150°
7. Rotate the crankshaft to check correct operation.
8. Remove excess sealant which may squeeze out at the front cover sealing surfaces.
9. CAUTION: Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
CAUTION: Make sure all components are clean and dry.
Make sure the transit sleeve is correctly in place and install the new seal over the crankshaft.
10. Carefully remove the transit sleeve, leaving the seal in place.
11. Install the special tool to the crankshaft.
12. Reposition the nuts to hold the special tool against the crankshaft rear seal. Check that the crankshaft rear seal and the special tool are parallel to the rear of the engine.
13. CAUTION: Alternate nut tightening to correctly seat the crankshaft rear seal.
Using the special tool, install the crankshaft rear seal.
14. Remove the special tool from the crankshaft.
^ Check that the seal is located correctly.
15. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surfaces.
Install special tools to the connecting rods.
^ Position the crankshaft journal at the bottom of the stroke.
16. CAUTION: Make sure the piston rings are positioned at different positions opposite the thrust side of the piston before installation.
CAUTION: Install pistons with arrow to front of engine.
Using the special tool compress the rings and install the piston and connecting rod.
^ Lubricate all piston components.
17. CAUTION: When assembling the connecting rods and connecting rod caps it is imperative that bearing slots and tangs be located on the same side of the connecting rods.
CAUTION: Connecting rod bolts are torqued to yield and must be replaced.
CAUTION: Bolts must be tightened equally.
NOTE: Remove the special tools from the connecting rods.
Position the connecting rod cap on the appropriate connecting rod.
11. Tighten to 10 Nm
12. Tighten to 30 Nm
13. Tighten to 90°
18. Rotate the crankshaft to check correct operation.
19. Install the piston cooling jets.
^ Tighten to 9 Nm
20. Install the oil pump.
^ Install a new gasket.
^ Tighten to 12 Nm.
21. Install the upper oil pan.
^ Install a new gasket.
^ Tighten to 21 Nm.
22. Install the oil strainer.
^ Install a new O-ring seal.
^ Tighten to 12 Nm.
23. Install the oil pan.
^ Install a new gasket.
^ Install, but do not fully tighten the retaining bolts.
24. Tighten to 12 Nm.
^ Tighten in the sequence shown.
^ A new oil pan is supplied with the drain plug installed. Check that the drain plug is tightened to 25 Nm.
25. Install the flexplate.
14. Install the flexplate.
15. Install the flexplate retaining bolts.
^ Tighten to 15 Nm.
^ Tighten to 110 Nm.
26. Reposition the crankshaft.
^ Install the crankshaft setting peg 303-645 to the crankshaft position sensor location.
27. Install a new left-hand cylinder head gasket.
^ Make sure the cylinder head dowels are correctly located.
28. CAUTION: Tighten the bolts 1 to 10 in the sequence shown.
Install the left-hand cylinder head.
16. Tighten bolts 1 to 10 to 20 Nm.
17. Tighten bolts 1 to 10 to 35 Nm.
18. Tighten bolts 1 to 10 to 90°.
19. Tighten bolts 1 to 10 to 90°.
20. Tighten bolts 11 to 12 to 25 Nm.
29. Install a new right-hand cylinder head gasket.
^ Make sure the cylinder head dowels are correctly located.
30. CAUTION: Tighten the bolts 1 to 10 in the sequence shown.
Install the right-hand cylinder head.
21. Tighten bolts 1 to 10 to 20 Nm.
22. Tighten bolts 1 to 10 to 35 Nm.
23. Tighten bolts 1 to 10 to 90°.
24. Tighten bolts 1 to 10 to 90°.
25. Tighten bolts 11 to 12 to 25 Nm.
31. NOTE: Make sure all components are clean.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
^ To the upper face of each bearing surface in the cylinder head.
^ To the upper face of each bearing surface in each bearing cap.
^ On the cam lobes ONLY, not on the base circle area.
32. Install the left-hand inlet camshaft.
33. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
^ Tighten to 10 Nm.
34. NOTE: Make sure all components are clean.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
^ To the upper face of each bearing surface in the cylinder head.
^ To the upper face of each bearing surface in each bearing cap.
^ On the cam lobes ONLY, not on the base circle area.
35. Install the left-hand exhaust camshaft.
36. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
^ Tighten to 10 Nm.
37. NOTE: Make sure all components are clean.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
^ To the upper face of each bearing surface in the cylinder head.
^ To the upper face of each bearing surface in each bearing cap.
^ On the cam lobes ONLY, not on the base circle area.
38. Install the right-hand inlet camshaft.
39. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
^ Tighten to 10 Nm.
40. NOTE: Make sure all components are clean.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
^ To the upper face of each bearing surface in the cylinder head.
^ To the upper face of each bearing surface in each bearing cap.
^ On the cam lobes ONLY, not on the base circle area.
41. Install the right-hand exhaust camshaft.
42. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
^ Tighten to 10 Nm.
43. Install the camshaft setting tool.
44. Install the camshaft setting tool.
45. CAUTION: Do not tighten the camshaft sprocket retaining bolts.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
^ Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
46. Using a suitable tool, retain the left-hand timing chain tensioner piston.
47. Release the tension in the left-hand timing chain tensioner.
^ Remove the retaining tool.
48. Install the secondary timing chain tensioner.
^ Tighten to 12 Nm.
49. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
^ Reposition the camshaft sprockets for the most advantageous position for use of the tool.
50. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.
51. Install the crankshaft sprocket.
52. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.
Install the primary timing chain.
^ Install the primary chain over the crankshaft sprocket and the intake sprocket.
53. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.
54. CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
55. NOTE: The timing chain tensioner piston should retract with minimal force. If binding occurs, reposition the timing chain tensioner to eliminate side loading.
Slowly compress the left-hand timing chain tensioner.
56. NOTE: The retaining tool must remain in the timing chain tensioner until the timing chain tensioner is installed to the engine with the piston bottomed in the bore.
Using a suitable tool, retain the left-hand timing chain tensioner piston.
57. Install the primary timing chain tensioner assembly.
^ Tighten to 12 Nm.
58. Release the tension in the left-hand timing chain tensioner.
^ Remove the retaining tool.
59. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side.
^ Tighten to 120 Nm.
60. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction.
^ Tighten to 120 Nm.
61. CAUTION: Do not tighten the camshaft sprocket retaining bolts.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
^ Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
62. Using a suitable tool, retain the right-hand timing chain tensioner piston.
63. Install the secondary timing chain tensioner retaining bolts.
^ Tighten to 12 Nm.
64. Release the tension in the right-hand timing chain tensioner.
^ Remove the retaining tool.
65. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
^ Reposition the camshaft sprockets for the most advantageous position for use of the tool.
