:	Aug 6, 2007

Timing Pin - Automatic Transmission
303-1117




Timing Pin - Manual Transmission
303-1116




Camshaft pulley holding tool
303-1145/1




Holder - Camshaft Pulleys Front
303-1124




Flex plate locking tool
303-947




Locking Tool - Flywheel
303-1123




Timing Pin - Camshaft Pulleys
303-1126

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:   Clean the component mating faces. :   It is important that the oil pan extension is bolted to the crankshaft main bearing carrier within twenty minutes of applying the sealant. Apply an 8 mm bead of sealant to the cylinder block in the areas shown.   Use WSS-M4G323-A4-RTV sealant.

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:   Clean the component mating faces. Install the oil pan extension.   Install a new gasket.   Loosely install the bolts.

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: Tighten the bolts in the indicated sequence in 2 stages. Secure the oil pan extension.   .  Tighten bolts A to 10 Nm (7 lb.ft). Tighten bolts B to 4 Nm (2 lb.ft).   .  Tighten bolts A to 24 Nm (18 lb.ft). Tighten bolts B to 10 Nm (7 lb.ft).

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:   Lubricate the new seals with clean engine oil. :   Clean the components. Install the oil pump screen and pickup tube.   Clean the components.   Install new O-ring seals.   Tighten the bolt to 10 Nm (7 lb.ft).

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:   Clean the component mating faces. Install the oil pan.   Install a new gasket.   Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).

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Install the fuel injection pump.   Tighten the bolts to 23 Nm (17 lb.ft).

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: Make sure the gasket is installed correctly. :   Clean the component mating faces. Install the oil cooler assembly.   Install a new gasket.   Install a new O-ring seal.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the crankshaft position (CKP) sensor.   Tighten the bolt to 5 Nm (4 lb.ft).   Connect the electrical connector.   Reposition the access cover.

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: Tighten the bolts in a diagonal sequence.   : Tighten the bolts in the stages shown. :   Clean the component mating faces. Install the flexplate.   Using the special tool, lock the flexplate.   Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).   Stage 2:Tighten the bolts 45 degrees.   Stage 3:Tighten the bolts a further 45 degrees.   Remove the special tool.

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Using the special tool, lock the flexplate.   Rotate the crankshaft clockwise to align the crankshaft alignment hole in the flywheel or flexplate with the cylinder block aperture.   Install a starter motor bolt to retain the special tool.

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Install the special tool.

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: Tighten the bolts in a diagonal sequence.   : Tighten the bolts in the stages shown. :   Clean the component mating faces. Install the flywheel.   Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).   Stage 2:Tighten the bolts 45 degrees.   Stage 3:Tighten the bolts a further 45 degrees.

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: Install the clutch disc with 'TRANSMISSION SIDE' marking against the clutch cover.   : Use the special tool to align the components.   : Working in a diagonal sequence, progressively tighten the bolts. :   Clean the component mating faces. Using the special tool, install the clutch disc and pressure plate.   Tighten the bolts to 25 Nm (18 lb.ft).

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Remove the special tool.

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Using the special tool, lock the flywheel.   Rotate the crankshaft clockwise to align the crankshaft alignment hole in the flywheel or flexplate with the cylinder block aperture.   Install a starter motor bolt to retain the special tool.

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Check the LH cylinder head face for distortion, across the center and from corner to corner.

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:   The cylinder head gasket must be installed over the cylinder head to cylinder block dowels. :   Clean the component mating faces. Install a new LH cylinder head gasket.

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: Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.   : Make sure that new bolts are installed. :   The cylinder head gasket must be installed over the cylinder head to cylinder block dowels. :   Make sure the cylinder head is installed in its original position. :   Tighten the bolts in the indicated sequence in 4 stages. :   Clean the component mating face. Install the LH cylinder head assembly.   Stage 1: Tighten the bolts to 20 Nm (15 lb.ft).   Stage 2: Tighten the bolts to 40 Nm (30 lb.ft).   Stage 3: Tighten the bolts to 80 Nm (59 lb.ft).   Stage 4: Tighten the bolts a further 180 degrees.

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Check the RH cylinder head face for distortion, across the center and from corner to corner.

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:   The cylinder head gasket must be installed over the cylinder head to cylinder block dowels. :   Clean the component mating faces. Install a new RH cylinder head gasket.

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: Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or cylinder head gasket may result.   : Make sure that new bolts are installed. :   The cylinder head gasket must be installed over the cylinder head to cylinder block dowels. :   Make sure the cylinder head is installed in its original position. :   Tighten the bolts in the indicated sequence in four stages. Install the RH cylinder head assembly.   Stage 1: Tighten to 20 Nm (15 lb.ft).   Stage 2: Tighten to 40 Nm (30 lb.ft).   Stage 3: Tighten to 80 Nm (59 lb.ft).   Stage 4: Tighten a further 180 degrees.

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Install the secondary timing chain to the RH bank camshafts.

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: Do not release the secondary timing chain tensioner locking pin until all of the camshaft bearing caps have been installed. Install the RH bank secondary timing chain tensioner.   Align the marks on the camshafts with the marks on the secondary timing chain.

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:   Clean the components. :   Install a new seal. Install the RH bank camshafts and secondary timing chain tensioner assembly.   Lubricate the journals and camshaft lobes.

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Secure the RH bank secondary timing chain tensioner.   Tighten the bolts to 10 Nm (7 lb.ft).

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: Tighten the bolts evenly in 3 stages in the sequence shown. :   Do not install the two exhaust camshaft end bearing caps at this stage. :   Clean the component mating faces. Install the RH bank camshaft bearing caps.   Stage 1: Tighten to 1 Nm (1 lb.ft).   Stage 2: Tighten to 5 Nm (4 lb.ft).   Stage 3: Tighten to 10 Nm (7 lb.ft).

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Apply sealant to the RH exhaust camshaft end bearing cap at the positions shown.

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: Tighten the bolts in the sequence shown. :   Clean the component mating faces. Install the RH bank exhaust camshaft end bearing caps.   Stage 1: Tighten to 1 Nm (1 lb.ft).   Stage 2: Tighten to 5 Nm (4 lb.ft).   Stage 3: Tighten to 10 Nm (7 lb.ft).

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Release the RH bank secondary timing chain tensioner piston.   Remove the locking pin.

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Install the secondary timing chain to the LH bank camshafts.

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: Do not release the secondary timing chain tensioner locking pin until all of the camshaft bearing caps have been installed. Install the LH bank secondary timing chain tensioner.   Align the marks on the camshafts with the marks on the secondary timing chain.

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:   Clean the components. :   Install new seals. Install the LH bank camshafts and secondary timing chain tensioner assembly.   Lubricate the journals and camshaft lobes.

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Secure the LH bank secondary timing chain tensioner.   Tighten the bolts to 10 Nm (7 lb.ft).

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: Tighten the bolts evenly in 3 stages in the sequence shown. :   Do not install the two exhaust camshaft end bearing caps at this stage. :   Clean the component mating faces. Install the LH bank camshaft bearing caps.   Stage 1: Tighten to 1 Nm (1 lb.ft).   Stage 2: Tighten to 5 Nm (4 lb.ft).   Stage 3: Tighten to 10 Nm (7 lb.ft).

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Apply sealant to the 2 LH exhaust camshaft end bearing caps at the positions shown.

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: Tighten the bolts in the sequence shown. :   Clean the component mating faces. Install the LH bank exhaust camshaft end bearing caps.   Stage 1: Tighten the bolt to 1 Nm (1 lb.ft).   Stage 2: Tighten the bolt to 5 Nm (4 lb.ft).   Stage 3: Tighten the bolt to 10 Nm (7 lb.ft).

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Release the LH bank secondary timing chain tensioner piston.   Remove the locking pin.

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Install the fuel injection pump belt rear cover.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the camshaft rear pulley.   Install a new camshaft pulley bolt.

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Install the special tool to the camshaft rear pulley.   Install and tighten the bolt.

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: Tighten the bolts in the stages shown. Secure the camshaft rear pulley.   Stage 1: Tighten the bolt to 40 Nm (30 lb.ft).   Stage 2: Tighten the bolt to 75 Nm (56 lb.ft).

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Remove the special tools.   Remove the bolt.

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: Do not install the new fuel injection pump belt to the pulleys with the fuel pump belt tensioner installed. Failure to follow this instruction may result in damage to the fuel pump belt. :   The fuel injection pump rotates in a counter-clockwise direction when viewed from the rear of the engine. Install the new fuel injection pump belt.

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: Make sure that the fuel injection pump belt tensioner locking pin is not removed until the fuel injection pump belt tensioner is fully installed.   : Make sure that the fuel injection pump belt tensioner tang is correctly located to the fuel injection pump belt rear cover. Failure to follow this instruction may result in damage to the engine. Install a new fuel injection pump belt tensioner.   Locate the tang on the new fuel injection pump belt tensioner into the fuel injection pump rear cover.   Tighten the bolt to 25 Nm (18 lb.ft).   Remove and discard the fuel injection pump belt tensioner locking pin.

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Install the fuel injection pump belt cover.

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Install the cooling fan drive hub bearing.   Tighten the bolts to 90 Nm (66 lb.ft).

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: Make sure that new bolts are installed. :   LH is shown, RH is similar. :   Clean the component mating faces. Using the special tool, install the 2 camshaft pulley hubs.   Stage 1: Tighten to 80 Nm (59 lb.ft).   Stage 2: Tighten a further 90 degrees.

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Install the 2 exhaust camshaft pulleys.   Install the bolts, but do not tighten fully at this stage.

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Install the special tools.   Rotate the camshafts.

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Install the 2 timing belt idler pulleys.   Install the plastic shield behind the upper idler pulley.   Tighten the bolts to 45 Nm (33 lb.ft).

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Rotate both camshaft pulleys clockwise.

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Install a new timing belt tensioner.   Install a new bolt, but do not fully tighten at this stage.

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: Make sure the camshaft pulleys remain in the clockwise position. Install the new timing belt.   Starting at the crankshaft pulley, install the timing belt in a counter-clockwise direction, in the sequence shown.   Stage 1: Attach the timing belt to the crankshaft pulley.   Stage 2: Attach the timing belt to the idler pulley.   Stage 3: Attach the timing belt to the left-hand camshaft pulley.   Stage 4: Attach the timing belt to the idler pulley.   Stage 5: Attach the timing belt to the RH camshaft pulley.   Stage 6: Attach the timing belt to the timing belt tensioner.

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: Make sure the timing belt tensioner window is aligned with the groove. Tension the timing belt.   Rotate the tensioner assembly counter-clockwise.   Tighten the bolt to 24 Nm (18 lb.ft).

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: Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools. Secure the camshaft pulleys.   Using a suitable tool, hold the camshaft pulley center bolts.   Tighten the bolts to 23 Nm (17 lb.ft).

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Remove the special tools.

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Remove the special tool.   Remove the bolt.

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Remove the special tool.   Remove the bolt.

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Rotate the engine two complete turns clockwise.

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Using the special tool, lock the flexplate.   Install a starter motor bolt to retain the special tool.

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Using the special tool, lock the flywheel.   Install a starter motor bolt to retain the special tool.

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Install the special tools to the exhaust camshaft pulleys.   If the special tool does not fit correctly, repeat the timing belt installation procedure.   Remove the special tools from the camshaft pulleys.

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Remove the special tool.   Remove the bolt.

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Remove the special tool.   Remove the bolt.

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:   Remove and discard the blanking caps. Install a new fuel injector return line.

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:   Remove and discard the blanking caps. Connect the fuel pipe to the fuel cooler.

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:   Install new O-ring seals. :   Clean the component mating faces. Install the cylinder head coolant outlet assembly.   Tighten the bolts to 10 Nm (7 lb.ft).

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:   Install new O-ring seals. Install the turbocharger oil supply line.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the breather line.   Secure the clip.   Tighten the bolt to 10 Nm (7 lb.ft).

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:   Clean the component mating faces. :   Install a new gasket. Install the brake vacuum pump.   Install the bracket.   Tighten the bolts to 23 Nm (17 lb.ft).

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:   Clean the component mating faces. :   Install a new gasket. Install the RH valve cover.   Tighten the bolts to 10 Nm (7 lb.ft).   Secure the glow plug electrical connector in the valve cover.   Secure the knock sensor (KS) electrical connector in the valve cover.

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Install the RH engine cover locating studs.   Install the bracket.   Tighten the nut to 10 Nm (7 lb.ft).   Tighten the bolt to 10 Nm (7 lb.ft).

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:   Clean the component mating faces. :   Install anew gasket. Install the LH valve cover.   Tighten the bolts to 10 Nm (7 lb.ft).   Secure the KS electrical connector in the valve cover.

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Install the LH engine cover locating studs.

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Install the fuel rail brackets.   Tighten the bolts to 23 Nm (17 lb.ft).

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Install the fuel rails.   Install the bolts, but do not tighten fully at this stage.

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:   Remove and discard the blanking caps. Install the new RH fuel rail high-pressure supply line.   Tighten the fuel injection supply manifold retaining bolts to 23 Nm (17 lb.ft).   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).   Secure the clip.

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:   Remove and discard the blanking caps. Install the new LH fuel rail high-pressure supply line.   Tighten the fuel injection supply manifold retaining bolts to 23 Nm (17 lb.ft).   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 30 Nm (22 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).   Secure the clip.

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:   Remove and discard the blanking caps. Install the new fuel diverter rail high-pressure supply line.   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection pump to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection pump to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 30 Nm (22 lb.ft).

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:   Remove and discard the blanking caps. Install the new RH fuel rail high-pressure supply line.   Tighten the fuel injection supply manifold retaining bolts to 23 Nm (17 lb.ft).   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection pump to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection pump to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).   Secure the clip.

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:   Remove and discard the blanking caps. Install the new LH fuel rail high-pressure supply line.   Tighten the fuel injection supply manifold retaining bolts to 23 Nm (17 lb.ft).   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection pump to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection pump to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).   Secure the clip.

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: Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.   : Do not use tools to install the new fuel return line retaining clip. Failure to follow this instruction will result in damage to the retaining clip. Install a new fuel injector clamp.   1. Install the fuel injector retaining clamp spacer.   2. Install a new fuel return line retaining clip.   3. Install a new sealing washer.

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Install the fuel injector.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the remaining fuel injectors.

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: Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter to enter the fuel injection system.   : Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel rail cones while installing unions. :   Remove and discard the blanking caps. Install the new high-pressure fuel injector supply lines.   Stage 1: Tighten the high-pressure fuel supply line union at the injector to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the injector to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel rail to 30 Nm (22 lb.ft).

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: Make sure the fuel return line retaining clip is correctly installed to the fuel injector before installing the return line. Connect the fuel return line to the fuel injectors.   Apply a light coating of petroleum jelly to the fuel return line O-ring seals.

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Install the engine wiring harness.   Tighten the nut to 10 Nm (7 lb.ft).   Secure the clips.

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Connect the fuel injection pump electrical connectors.

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Connect the fuel rail pressure (FRP) sensor electrical connector.

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Install the crankcase vent oil separator.   Connect and secure the 2 breather hoses.

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Connect the fuel temperature sensor electrical connector.

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:   LH shown, RH is similar. Connect the 2 KS electrical connectors.

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Connect the engine oil temperature sensor electrical connector.   Secure the wiring harness clip.

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Connect the camshaft position (CMP) sensor electrical connector.   Secure the wiring harness clip.

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:   RH shown, LH is similar Connect the 6 fuel injector electrical connectors.   Secure the 4 wiring harness clips.

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Connect the engine oil pressure (EOP) sensor electrical connector.   Secure the wiring harness clip.

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Install the 2 low pressure fuel pipes.

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Install the timing belt cover.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the crankshaft pulley.   Tighten the bolts to 14 Nm (10 lb.ft).

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Install the cooling fan pulley.   Tighten the bolts to 23 Nm (17 lb.ft).

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Install the accessory drive belt idler.   Tighten the bolt to 47 Nm (35 lb.ft).

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:   Clean the component mating faces. :   Install a new O-ring seal. Install the coolant pump.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the exhaust gas recirculation (EGR) valve coolant pipe.   Install the bolt.   Connect the electrical connector.   Secure in the 2 clips.   Secure the clip.

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: Make sure that new nuts are installed. :   Tighten the nuts in the sequence shown. :   Install a new gasket. Install the RH exhaust manifold and exhaust cross-over pipe assembly.   Tighten the nuts to 24 Nm (18 lb.ft).

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Install the generator bracket.   Tighten the bolts to 23 Nm (17 lb.ft).

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Install the RH engine mount bracket.   Tighten the bolts to 110 Nm (81 lb.ft).

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Install the RH exhaust manifold heat shield.   Tighten the bolts to 10 Nm (7 lb.ft).

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: Tighten the bolts in the sequence shown. Install the generator.   Tighten the bolts to 47 Nm (35 lb.ft).

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Connect the generator electrical connectors.   Tighten the nut to 12 Nm (9 lb.ft).   Reposition the rubber insulator.

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Install the RH EGR valve and cooler assembly.   Tighten the bolts to 10 Nm (7 lb.ft).   Connect the coolant hose and secure with the clip.   Connect the electrical connector.   Install and secure the new clip.

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:   Install a new O-ring seal. Install the cylinder block coolant inlet pipe.   Tighten the bolts to 10 Nm (7 lb.ft).

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: Make sure that new nuts are installed. :   Tighten the nuts in the sequence shown. :   Install a new gasket. Install the LH exhaust manifold and turbocharger assembly.   Tighten the nuts to 24 Nm (18 lb.ft).

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: Make sure that new nuts are installed. :   Install a new gasket. Secure the exhaust cross-over pipe to the LH exhaust manifold.   Tighten the nuts to 24 Nm (18 lb.ft).

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:   Remove and discard the blanking caps. :   Install new sealing washers. Connect the turbocharger oil supply tube.   Tighten the banjo bolt to 30 Nm (22 lb.ft).

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Secure the turbocharger support bracket.   Tighten the bolts to 23 Nm (17 lb.ft).

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:   Remove and discard the blanking caps. :   Install a new O-ring seal. :   Install a new gasket. Install the turbocharger oil return tube.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the turbocharger heat shield.   Tighten the bolts to 10 Nm (7 lb.ft).

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Install the LH exhaust manifold heat shield.   Tighten the bolts to 10 Nm (7 lb.ft).

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:   Install a new clip. Install the LH EGR valve and cooler assembly.   Install the support bracket.   Tighten the bolts to 10 Nm (7 lb.ft).   Connect the coolant hose and secure with the clip.   Connect the electrical connector.   Install and secure the clip.

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:   Remove and discard the blanking caps. :   Install a new O-ring seal. Install the oil level indicator and tube.   Tighten the bolt to 10 Nm (7 Lb.ft).   Secure the wiring harness clip.

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Install the LH engine mount bracket.   Tighten the bolts to 110 Nm (81 lb.ft).

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Install the air conditioning (A/C) compressor bracket.   Tighten the bolts to 23 Nm (17 lb.ft).

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Install the A/C compressor.   Tighten the bolts to 23 Nm (17 lb.ft).   Connect the electrical connector.

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Install the power steering pump bracket.   Tighten the bolts to 23 Nm (17 lb.ft).

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Remove the engine from the engine stand.

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Install the engine.

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Fill the engine with the recommended oil to the correct level.