Steps 41-80

Engine













Upper Engine









Timing Drive









Lower Engine













NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Procedures.

41. Tighten the bolts in the sequence shown in 6 stages.
- Stage 1: Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.

- Stage 2: Tighten bolts 1 through 16 to 10 Nm (89 lb-in).

- Stage 3: Tighten bolts 17 through 20 to 10 Nm (89 lb-in).

- Stage 4: Tighten bolts 1 through 16 an additional 45 degrees.

- Stage 5: Tighten bolts 17 and 19 an additional 70 degrees.

- Stage 6: Tighten bolts 18 and 20 an additional 53 degrees.





42. Check the valve clearance. For additional information, refer to Valve Clearance Check Adjustments.

43. Using the Camshaft Seal Installer, install the 2 camshaft oil seals.





44. NOTICE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.

Install the Camshaft Alignment Plate into the end of the camshafts.





45. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

NOTE: The timing marks of the camshaft phaser and sprocket must be at the 12 o'clock position.

Install the 2 camshaft phaser and sprocket, bolts and the VCT Alignment Tool.

- Tighten the 2 bolts to 25 Nm (18 lb-ft).





46. Remove the VCT Alignment Tool.





47. Remove the Camshaft Alignment Plate.





48. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.





49. NOTE: The special tool can only be installed if the valve timing is correct.

Install the Camshaft Alignment Plate into the end of the camshafts.





50. NOTE: The special tool can only be installed if the valve timing is correct.

Install the VCT Alignment Tool.

- If the special tools cannot be installed, repeat the adjustment according to the preceding steps.





51. Remove the VCT Alignment Tool.





52. Remove the Camshaft Alignment Plate.





53. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

Install the 2 camshaft phaser and sprocket plugs.

- Tighten to 16 Nm (142 lb-in).





54. Install the VCT Alignment Tool.





55. Install the 4 spark plugs.
- Tighten to 15 Nm (133 lb-in).





56. Using a new gasket, install the coolant pump and the 6 bolts.
- Tighten to 10 Nm (89 lb-in).





57. Install the timing belt tensioner and the bolt.
- Tighten to 20 Nm (177 lb-in).

- Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a small screwdriver or holding pin.





58. NOTE: Lubricate the oil seal with clean engine oil.

Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Front Crankshaft Seal Replacer, install the crankshaft front oil seal.





59. Install the crankshaft sprocket gear.





60. Install the timing belt cover backplate and the 4 bolts.
- Tighten to 9 Nm (80 lb-in).





61. Install the timing belt in the sequence shown.





62. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

Remove the timing belt tensioner holding tool.





63. Install the lower timing belt cover and the 3 bolts.
- Tighten to 9 Nm (80 lb-in).





64. Install the crankshaft pulley and the new bolt.
- Tighten to 100 Nm (74 lb-ft).

- The final torque of the crankshaft will be completed in following steps.





65. Remove the Crankshaft TDC Timing Pin.





66. Remove the VCT Alignment Tool.





67. Tighten the crankshaft bolt in the following 3 stages.

1. Stage 1: Using the Strap wrench, tighten an additional 90 degrees.

2. Stage 2: Wait for 10 seconds.

3. Stage 3: Using the Strap wrench, tighten an additional 15 degrees.





68. NOTE: Only rotate the crankshaft clockwise direction.

Rotate the crankshaft about 1 3/4 turns.





69. Install the Crankshaft TDC Timing Pin.





70. NOTE: Only rotate the crankshaft clockwise direction.

Rotate the crankshaft until it stops against the Crankshaft TDC Timing Pin.





71. NOTE: The special tool can only be installed if the valve timing is correct.

Install the VCT Alignment Tool.

- If the special tool cannot be installed, repeat the adjustment according to the preceding steps.





72. Remove the VCT Alignment Tool.





73. Remove the Crankshaft TDC Timing Pin.





74. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).





75. Install the engine mount bracket and the 3 bolts finger tight.

1. Tighten the 2 bolts to 55 Nm (41 lb-ft).

2. Tighten the bolt to 55 Nm (41 lb-ft).





76. Install the timing belt cover and the 9 bolts.
- Tighten to 9 Nm (80 lb-in).





77. Install the coolant pump pulley and the 4 bolts.
- Tighten to 20 Nm (177 lb-in).





78. Install the 1 engine mount stud finger tight.





79. NOTICE: The 2 engine mount studs must be torqued or damage to the powertrain may occur.

Torque the 2 engine mount studs before installing the engine mount nuts.

- Tighten to 8 Nm (71 lb-in).





80. Using a new gasket, install the valve cover and tighten the retainers in sequence shown.
- Tighten to 9 Nm (80 lb-in).