:  Mar 7, 2008





Timing Setting tool
303-645




Camshaft setting/locking tool
303-530




Adapter - Crankshaft seal installer
303-1100-01




Adapter
303-191-03




Holding Tool Crankshaft Pulley
303-893(LRT-12-080)




Bolts and spacers
303-191-04




Timing chain tensioning tool
303-532




. Secure the engine to the engine stand.
 
  • Align the engine to the engine stand.
    •  
  • Adjust the engine stand legs into position.
    •  
  • Mount the engine to an engine stand.
    •  
  • Fully tighten the engine stand leg nuts.

    • . :
      Install a new gasket.

    Install the oil pump assembly.
     
  • Clean the component mating faces.
    •  
  • Install the gasket.
    •  
  • Tighten the bolts to 10 Nm (7 lb.ft).




    • . Install the baffle plate.
     
  • Tighten the 6 bolts to 6 Nm ( 4 lb.ft).




    • . :
      Install a new O-ring seal.

    Install the oil strainer pick-up assembly.
     
  • Install the O-ring seal.
    •  
  • Tighten the M6 bolt to 10 Nm (7 lb.ft).
    •  
  • Apply sealant to the M5 bolts.
    •  
  • Tighten the M5 bolts to 6 Nm (4 lb.ft).




    • . Install the oil pan.
     
  • Clean the component mating faces.
    •  
  • Apply a 3 mm (0.118 in) diameter bead of sealant, to the area indicated.
    •  
  • Install the bolts, but do not tighten fully at this stage.




    • . Tighten the oil pan bolts in the sequence shown to 20 Nm (15 lb.ft).



    . :
      Prevent the flexplate from rotating.

    Install the flexplate.
     
  • Clean the component mating faces.
    •  
  • Tighten the bolts evenly in 2 stages to the sequence shown.
    •  
  • Tighten the bolts to 15 Nm (11 lb ft).
    •  
  • Tighten the bolts to 110 Nm (81 lb.ft).




    • . Install the coolant pump.
     
  • Tighten the 5 bolts to 10 Nm (7 lb.ft).




    • . :
      Some variation in the illustrations may occur, but the essential information is always correct.

    Install the knock sensors (KS).
     
  • Tighten the bolts to 20 Nm.




    • . Position the starter motor.
     
  • Install the starter motor. TORQUE: 45 Nm




    • . Attach the engine mounting bracket.



    . :
      The cylinder head gaskets must be installed over the cylinder head to block dowels.

    Install the RH cylinder head.
     
  • Clean the component mating faces.
    •  
  • Clean the cylinder head locating dowels.
    •  
  • Install a new cylinder head gasket.
    •  
  • With assistance install the cylinder head.
    •  
  • Repeat the operation for the LH side.




    • . :
      Tighten the bolts 1 to 10 in the sequence shown.

    :
      LH illustration shown, RH is similar.

    Install the cylinder head bolts.
     
  • Tighten the bolts to 20 Nm (15 lb.ft).
    •  
  • Tighten the bolts to 35 Nm (26 lb.ft).
    •  
  • Tighten the bolts 1 to 10, a further 90 degrees.
    •  
  • Tighten the bolts 1 to 10, a further 90 degrees.
    •  
  • Tighten the M8 bolts 11 and 12, to 25 Nm (18 lb.ft).
    •  
  • Repeat the operation for the LH side.




    • . Install the LH camshafts.
     
  • Clean the component mating faces.
    •  
  • Lubricate the journals and camshaft lobes.

    • . Install the camshaft bearing caps.
     
  • Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).




    • . Install the sprocket retaining Torx bolts to the camshafts.

    .
      : Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.

    Measure and record the tappet clearances.
     
  • Rotate the camshafts using the Torx bolts.




    • . :
      Remove the camshaft bearing caps evenly and in stages.

    :
      Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).

    Remove the camshafts.
     
  • Remove the 20 bolts.




    • . Remove the valve tappets, replace with selected tappets.

    . Install the camshafts.
     
  • Lubricate the journals and camshaft lobes.
    •  
  • Clean the component mating faces.

    • . Install the camshaft bearing caps.
     
  • Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).




    • .
      : Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.

    Check valve tappet clearances are correct.
     
  • Rotate the camshafts using the Torx bolts.
    •  
  • Remove the camshaft Torx bolts after the check is complete.




    • . Repeat the operation for the RH camshafts.

    . Install the special tool to the LH cylinder head.



    . :
      RH illustration shown, LH is similar.

    Depress the LH secondary timing chain tensioner piston.
     
  • Using 1 mm diameter metal rod, retain the chain tensioner piston.




    • . Install the LH secondary timing chain tensioner retaining bolts.
     
  • Tighten the bolts to 12 Nm (9 lb.ft).




    • . :
      Lightly tighten the camshaft sprocket Torx bolts, the sprockets MUST be free to move.

    Install the LH secondary timing chain and sprockets to the camshafts.
     
  • Install the sprocket retaining Torx bolts to the camshafts.




    • . Tension the secondary timing chain.
     
  • Remove the retaining rod.




    • . Repeat the operation for the RH camshafts.

    . :
      RH illustration shown, LH is similar.

    Install the LH primary timing chain.
     
  • Make sure the timing chain slack is on the tensioner side of the timing chain.




    • . Install the LH primary chain tensioner guide.
     
  • Tighten the stud to 12 Nm (9 lb.ft).




    • .
      : 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.

    Install the LH primary timing chain tensioner.
     
  • Using 3 mm diameter metal rod, retain the chain tensioner piston.
    •  
  • Tighten the bolts to 12 Nm (9 lb.ft).
    •  
  • Remove the retaining rod.




    • .
      : Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side.

      : The intake camshaft sprocket retaining bolt MUST be tightened before the exhaust camshaft sprocket retaining bolt. Engine damage will occur if this procedure is not followed.

    Install the special tool to the exhaust camshaft sprocket.
     
  • Tighten the intake camshaft sprocket bolt to 20 Nm (15 lb.ft) then a further 90 degrees.
    •  
  • Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 lb.ft) then a further 90 degrees.




    • . Install the LH variable camshaft timing (VCT) oil control unit.
     
  • Install the new O-ring seals.
    •  
  • Tighten the new bolts to 22 Nm (16 lb.ft).
    •  
  • Tighten the nut to 10 Nm (7 lb.ft).




    • . Install the RH primary timing chain.
     
  • Make sure the timing chain slack is on the tensioner side of the timing chain.




    • . Install the RH primary timing chain tensioner guide.
     
  • Tighten the bolts to 12 Nm (9 lb.ft).




    • .
      : 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.

    Install the RH primary timing chain tensioner.
     
  • Using 3 mm diameter metal rod, retain the chain tensioner piston.
    •  
  • Tighten the bolts to 12 Nm (9 lb.ft).
    •  
  • Remove the retaining rod.




    • .
      : Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side.

      : The intake camshaft sprocket retaining bolt MUST be tightened before the exhaust camshaft sprocket retaining bolt. Engine damage will occur if this procedure is not followed.

      : Make sure that new bolts are installed.

    Install the special tool to the exhaust camshaft sprocket.
     
  • Tighten the intake camshaft sprocket bolt to 20 Nm (15 lb.ft) then a further 90 degrees.
    •  
  • Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 lb.ft) then a further 90 degrees.




    • . Install the RH VCT oil control unit.
     
  • Install the new O-ring seals.
    •  
  • Tighten the new bolts to 22 Nm (16 lb.ft).




    • . Remove the special tool from the LH cylinder head.



    . Remove the special tool from the RH cylinder head.



    . Remove the crankshaft locking tool.
     
  • Remove the screw.




    • . Install the engine front cover.
     
  • Clean the component mating faces.
    •  
  • Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places indicated.




    • . Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).



    . Using the special tools, install the crankshaft front seal.
     
  • Clean the component mating faces.
    •  
  • Lubricate the seal with clean engine oil.
    •  
  • Use the discarded crankshaft bolt with the service tool.




    • . Using the special tools, install the crankshaft front seal.
     
  • Clean the component mating faces.




    • . Install the crankshaft pulley.
     
  • Lubricate the seal with clean engine oil.

    • . Install the crankshaft pulley locking ring.

    .
      : The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt.

    Install, but do not tighten, the new crankshaft pulley bolt.

    .
      : Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.

    Using the special tools, retain the crankshaft pulley.
     
  • Tighten the crankshaft pulley bolt to 380 Nm (280 lb.ft).




    • . Remove the special tools.

    . Install new valve cover plug aperture gaskets.
     
  • Install a new valve cover gasket.




    • . :
      Apply two beads of silcone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.

    Install the valve cover.
     
  • Clean the component mating faces.




    • . Install the valve cover retaining bolts.
     
  • Install valve cover retaining bolts to their position previously noted.
    •  
  • Complete the tightening sequence as illustrated.
    •  
  • Tighten the bolts to 12 Nm (9 lb.ft).




    • . Install new valve cover plug aperture gaskets.
     
  • Install a new valve cover gasket.




    • . :
      Apply two beads of silcone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.

    Install the valve cover.
     
  • Clean the component mating faces.




    • . Install the valve cover retaining bolts.
     
  • Install valve cover retaining bolts to their position previously noted.
    •  
  • Tighten the bolts to 12 Nm (9 lb.ft).
    •  
  • Complete the tightening sequence as illustrated.




    • . Install the 8 ignition coil-on-plugs.
     
  • Install the 8 bolts.
    •  
  • Tighten the bolts to 6 Nm (4 lb.ft).




    • . Install the generator mounting bracket.
     
  • Clean the locating dowels.
    •  
  • Clean the component mating faces.
    •  
  • Tighten the bolts to 45 Nm (33 lb.ft).




    • . Install the A/C mounting bracket.



    . Install the coolant manifold.
     
  • Tighten the bolts to 6 Nm (4 lb.ft).




    • . Install the coolant pump pulley.
     
  • Tighten the bolts to 10 Nm (7 lb.ft).




    • . Install the accessory drive belt idler pulley.
     
  • Tighten the bolt to 25 Nm (18 lb.ft).




    • . With assistance, install the intake manifold.
     
  • Install the gaskets.
    •  
  • Evenly and progressively tighten the bolts to 20 Nm (15 lb.ft).




    • . Install the purge valve.
     
  • Secure the electrical harness with the clip.
    •  
  • Tighten the bolt to 6 Nm (4 lb.ft).
    •  
  • Connect and secure the electrical connector.




    • . Connect the starter motor positive cable.
     
  • Secure the cover.




    • . Connect the oil temperature and oil pressure sensors.



    . Install the generator.
     
  • Clean the component mating faces.
    •  
  • Tighten the bolts to 48 Nm (35 lb.ft).
    •  
  • Connect the generator electrical connector.
    •  
  • Secure the clips.




    • . Install the crankshaft position (CKP) sensor electrical connector.
     
  • Connect the CKP sensor electrical connector.




    • . Install the power steering pump mounting bracket.
     
  • Clean the component mating faces.
    •  
  • Tighten the bolts to 25 Nm (18 lb.ft).
    •  
  • Secure the transmission cooler pipes into clips.




    • . Connect and secure the CMP sensor electrical connectors.
     
  • Repeat the operation for the RH side.




    • . :
      Some variation in the illustrations may occur, but the essential information is always correct.

    Connect the KS electrical connector.



    . Connect the engine coolant temperature (ECT) sensor electrical connector.



    . Connect the ignition coil-on-plug electrical connections.
     
  • Install the clips.
    •  
  • Repeat the above procedure for the other side.




    • . Connect the VCT oil solenoid electrical connector.
     
  • Repeat the above procedure for the other side.
    •  
  • Connect the valve cover breather hose.




    • . Connect the cylinder head earth ground connector.
     
  • Install the bolt.
    •  
  • Secure the 3 clips.




    • . Install the ignition coil-on-plug cover.
     
  • Secure the clips.
    •  
  • Repeat the above procedure for the other side.




    • . Remove the engine from the engine stand.

    . Install the engine assembly.