Steps 1-60

Assembly





Special Tool(s)





Material

Part 1:

Part 2:

Part 1:

Part 2:

Part 3:

1. Position the oil pump and install the 4 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





2. Install the oil separator cover, a new gasket and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).









3. Position the Knock Sensor (KS) and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
^ Attach the wiring retainer to the oil separator cover.





4. NOTE: Lubricate the O-ring seal with clean engine coolant.

Install the coolant inlet tube, a new O-ring seal and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





5. NOTE: Lubricate the O-ring seal with clean engine coolant.

Install the coolant bypass tube, a new O-ring seal and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





6. CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive materials during cleaning of the surfaces. Hairline scratches, small burrs or dirt can provide a leak path for a cylinder head gasket. If gasket material remains on the sealing surface, use only a plastic tipped scraper to remove the material. Do not attempt to reuse the head gaskets.

CAUTION: Cylinder head bolts are torque to yield and cannot be reused.

NOTE: The LH and RH cylinder head gaskets are not interchangeable.

Position the new gaskets and the RH and LH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages.
^ Stage 1: Tighten to 30 Nm (22 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Back out a minimum of one full turn (360 degrees).
^ Stage 4: Tighten to 30 Nm (22 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees.
^ Stage 6: Tighten an additional 90 degrees.





7. NOTE: Be sure camshaft bearing caps are installed in their original positions.

Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.





8. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.

Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps and loosely install the bolts.





9. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the thrust caps and loosely install the bolts.





10. Tighten the bolts in the sequence shown.

11. NOTE: If new camshafts were installed, refer to Valve Clearance Adjustment.

Lubricate the tappet shims and camshaft lobes with clean engine oil.
12. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.





13. Install the LH Variable Camshaft Timing (VCT) actuator and install a new bolt hand tight. Use a wrench on the flats of the camshaft to hold it in position and tighten the bolt in 2 stages.
^ Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





14. Install the LH exhaust camshaft sprocket and install a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
^ Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





15. Install the RH Variable Camshaft Timing (VCT) actuator and install a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
^ Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





16. Install the RH exhaust camshaft sprocket and install a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
^ Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





17. With the 2 keyways facing forward, install the crankshaft sprockets.





18. If the timing marks in the timing chains are not evident, use a permanent type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1 Mark any link to use as the exhaust camshaft timing mark.
2 Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark.
3 Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.





19. Verify that the crankshaft keyway is in the 11 o'clock position.





20. CAUTION: The crankshaft keyway must remain in the 11 o'clock position until the cams are located in the NEUTRAL position, or damage to the valves can occur.

Rotate the LH and RH intake and exhaust camshafts to locate them in their NEUTRAL positions.





21. NOTE: The gold colored bolt must be installed in its original location.

Install the LH VCT solenoid housing assembly and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





22. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.





23. Install the LH timing chain tensioner arm.





24. NOTE: Be sure to position the tensioner so that the tensioner piston is fully engaged in the tensioner arm.

Install the LH timing chain tensioner and bolts.





25. Remove the wire or paper clip from the tensioner.





26. Rotate the crankshaft clockwise and position the keyway at the 3 o'clock position for RH timing chain installation.





27. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing marks on the camshaft and crankshaft sprockets.





28. Install the RH VCT solenoid housing assembly and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





29. Install the RH timing chain, aligning the copper or (marked) links with the marks on the camshaft and crankshaft sprockets.





30. Verify that the copper (or marked) links on the RH timing chain are in alignment with the timing marks on the camshaft and crankshaft sprockets.





31. Install the RH timing chain tensioner arm.





32. Install the RH timing chain tensioner and bolts.





33. Remove the wire or paper clip from the RH timing chain tensioner.





34. CAUTION: This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "20 25 30 DAMB 30 OFF" only. This slot is also marked with an orange paint mark and aligns with the missing tooth in the trigger wheel.

Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.
35. Install new gaskets on the engine front cover.





36. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.

NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 6 mm (0.24 inch) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
37. Install new gaskets on the engine front cover.





38. Install the engine front cover and the 15 bolts.
^ Tighten the bolts in the sequence shown to 25 Nm (18 ft. lbs.).





39. Install the Crankshaft Position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





40. Install the RH and LH Camshaft Position (CMP) sensors and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





41. Install the oil pan baffle and the 5 nuts.
^ Tighten to 20 Nm (15 ft. lbs.) and then rotate 45 degrees.





42. NOTE: Lubricate the new oil pump screen and pickup tube O-ring seal with clean engine oil.

Position the oil pump screen and pickup tube and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





43. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.

NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 10 mm (0.4 inch) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the 2 locations shown.





44. NOTE: The oil pan rear face must be installed flush to the cylinder block rear face to within + 0.10 mm (0.0039 inch). Failure to maintain this specification will require the oil pan to be removed and installed again.

Install a new gasket and the oil pan.
^ Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.





45. Tighten the oil pan bolts in the sequence shown.





46. NOTE: Clean and inspect all sealing surfaces. Inspect and install new gaskets as necessary.

Position the lower intake manifold and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





47. Install the fuel tube bracket bolt.
^ Tighten to 10 Nm (89 inch lbs.).

48. Install new gaskets in the RH valve cover.





49. NOTE: Clean the RH valve cover sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.

NOTE: The valve cover must be installed and the bolts tightened within 4 minutes of sealant application.

Apply an 8 mm (0.32 inch) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.





50. Position the RH valve cover and install the 12 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





51. Connect the crankcase vent tube to the RH valve cover.





52. Install the upper intake manifold support bracket and the 2 nuts.
^ Tighten to 6 Nm (53 inch lbs.).

53. Install new gaskets in the LH valve cover.





54. NOTE: Clean the LH valve cover sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.

NOTE: The valve cover must be installed and the bolts tightened within 4 minutes of sealant application.

Apply an 8 mm (0.32 inch) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.





55. Position the LH valve cover and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





56. Install the engine appearance cover bracket and the 2 nuts.
^ Tighten to 6 Nm (53 inch lbs.).





57. NOTE: The cylinder head temperature (CHT) sensor can not be reused. a new CHT must be installed

Install a new CHT.
^ Tighten to 15 Nm (11 ft. lbs.).





58. NOTE: RH shown, LH similar.

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the inside of the coil boots before installation.

Install the 6 ignition coils the 6 bolts.
^ Tighten to 7 Nm (62 inch lbs.).





59. Install the oil pressure switch and oil temperature sensor.
^ Tighten to 14 Nm (10 ft. lbs.).





60. Position the generator and install the 3 bolts.
^ Tighten to 48 Nm (35 ft. lbs.).