:	Nov 9, 2006

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Disconnect the battery ground cable.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Remove the engine.

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Mount the engine to an engine stand.

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Remove the air conditioning compressor (A/C) support bracket.   Remove the 2 bolts.

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Remove the cooling fan drive belt tensioner.   Remove the bolt.

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Remove the coolant manifold.   Release the clips and disconnect the 4 coolant hoses.   Remove the 4 bolts.   Disconnect the engine coolant temperature (ECT) sensor electrical connector.

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Remove the coolant pump and accessory drive belt idler pulleys.   Remove the bolts.

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Remove the exhaust manifold heat shield.   Remove the 2 bolts.

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Disconnect the battery positive cable.   Remove the battery positive cable cover.   Remove the nut.

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Remove the generator.   Disconnect the electrical connector.   Remove the 3 bolts.

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Remove the generator mounting bracket.   Remove the 4 bolts.

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: 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.

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:   The crankshaft pulley retaining bolt will be very tight. Using the special tools, remove the crankshaft pulley bolt.   Discard the bolt.   Remove the special tools.

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:   The crankshaft pulley will be very tight. Using the special tools, remove the crankshaft pulley.   Collect the locking ring.   Remove the special tools.

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Using the special tool, remove and discard the crankshaft front seal.

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Remove the RH ignition coil-on-plug cover.   Release from the 2 clips.

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Disconnect the RH ignition coil-on-plug electrical connector.

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Remove the RH ignition coil-on-plug.   Remove the bolt.   Remove and discard the seal.

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Remove the remaining ignition coil-on-plugs.

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Disconnect the positive crankcase ventilation (PCV) line.

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Disconnect the LH variable camshaft timing ( VCT) oil solenoid electrical connector.

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Disconnect the valve cover breather hose.

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Release the engine wiring harness from the retaining bracket.

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Disconnect the RH variable camshaft timing (VCT) oil solenoid electrical connector.

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:   Note the fitted position of the retaining bolts prior to removal. Remove the RH valve cover.   Remove the 14 valve cover retaining bolts.   Remove the engine cover bracket.

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Remove and discard the RH valve cover gaskets.   Remove and discard the seals.

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Remove the LH ignition coil-on-plug cover.   Release from the 2 clips.

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Disconnect the LH ignition coil-on-plug electrical connector.

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Remove the LH ignition coil-on-plug.   Remove the bolt.   Remove and discard the seal.

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Remove the remaining LH ignition coil-on-plugs.

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Remove the oil level indicator and tube.   Remove the oil level indicator.   Remove the nut.   Remove the tube.   Remove and discard the O-ring seal.

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Release the engine wiring harness from the retaining bracket.

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:   Note the fitted position of the retaining bolts prior to removal. Remove the LH valve cover.   Remove the 14 valve cover retaining bolts.

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Remove and discard the LH valve cover gaskets.   Remove and discard the seals.

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Release the engine wiring harness.   Release the 2 clips.   Remove the bolt.

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Remove the power steering pump mounting bracket.   Remove the 5 bolts.

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Release the wiring harness from the LH side of the engine.   Release the 3 clips.

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Release the wiring harness from the RH side of the engine.   Release the 3 clips.

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Remove the halfshaft support bearing housing.   Remove the 4 bolts.   Remove and discard the O-ring seal.

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Disconnect the crankshaft position (CKP) sensor electrical connector.

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Remove the CKP sensor.   Remove the bolt.

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:   Install the special tool to the crankshaft sensor aperture. Lock the crankshaft.   Install the special tool.   Install the screw.

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Remove the engine front cover.   Remove the 24 bolts.   Remove and discard the gasket.   Remove and discard the 3 O-ring seals.

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Remove the RH VCT housing.   Remove the 3 bolts.   Remove and discard the O-ring seals.

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Install the special tool to the RH cylinder head.   Install the 3 bolts.

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Remove the RH primary timing chain tensioner assembly.   Remove the 2 bolts.

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Remove the RH primary timing chain tensioner guide.   Remove the bolt.

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Remove the RH primary timing chain.

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Remove the LH VCT housing.   Remove the 3 bolts.   Remove and discard the O-ring seals.

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Install the special tool to the LH cylinder head.   Install the 3 bolts.

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Remove the LH primary timing chain tensioner.   Remove the 2 bolts.

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Remove the LH upper and lower primary timing chain tensioner guides.   Remove the 2 bolts.

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Remove the LH primary timing chain.

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:   Note the orientation of the crankshaft sprocket. Remove the crankshaft sprocket.   Remove the crankshaft sprocket key.

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Remove the special tool.

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Remove the torque converter flexplate.   Remove and discard the 8 bolts.

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: Note the position of the bolts, prior to removal. Remove the oil pan.   Remove the 17 bolts.   Remove and discard the gasket.

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Remove the oil strainer pick-up assembly.   Remove the 2 bolts.   Remove and discard the O-ring seal.

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Remove the oil pan extension.   Remove the 18 bolts.

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Remove the oil pump assembly.   Remove the 4 bolts.   Remove and discard the gasket.   Clean the component mating faces.

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Remove the baffle plate.   Remove the 6 bolts.

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: To make sure damage does not occur to the crankshaft and piston components, the engine must be inverted on the engine stand. Failure to follow this instruction may result in damage to the engine. Remove the crankshaft main bearing carrier.   Remove and discard the 34 bolts.

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Remove and discard the rear crankshaft oil seal.

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Clean the cylinder block and crankshaft main bearing carrier mating faces.

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:   The component must be installed within 20 minutes of the sealant application. :   Lubricate the crankshaft and main bearings with clean engine oil. :   Use WSS-M4G320-A3-RTV sealant. Apply a 2mm (0.08 in) diameter bead of sealant, to the area indicated.

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Install the crankshaft main bearing carrier.   Apply a 1mm (0.08 in) diameter bead of sealant, to the area indicated.   Install the bolts, but do not tighten fully at this stage.

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: Do not rotate the crankshaft until all the bolts are tightened to specification. Tighten the new bolts evenly in 8 stages to the sequence shown.   1) Tighten the bolts 21 to 32 to 15 Nm (11 lb.ft).   2) Tighten the bolts 33 to 34 to 15 Nm (11 lb.ft).   3) Tighten the bolts 1 to 10 to 25 Nm (18 lb.ft).   4) Tighten the bolts 11 to 20 to 15 Nm (11 lb.ft).   5) Tighten the bolts 1 to 10 to 35 Nm (26 lb.ft), then a further 135 degrees.   6) Tighten the bolts 11 to 20 to 20 Nm (15 lb.ft), then a further 150 degrees.   7) Tighten the bolts 21 to 32 to 20 Nm (15 lb.ft), then a further 90 degrees.   8) Tighten the bolts 33 to 34 to 20 Nm (15 lb.ft), then a further 150 degrees.

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

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:   Carefully remove the transit sleeve, leaving the seal in place. :   Make sure that the transit sleeve is correctly positioned and install the new seal over the crankshaft. Do not use any lubricant on the seal, the transit sleeve or the crankshaft. Using the special tool, position the crankshaft rear oil seal.   Install the special tool to the crankshaft.

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: Alternate the nut tightening to correctly seat the crankshaft rear oil seal. Using the special tool, install the rear crankshaft oil seal.

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: Make sure that the crankshaft rear oil seal is correctly located. Remove the special tool.

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:   Prevent the flexplate from rotating. Install the torque converter 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).

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Install the special tool.

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:   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).

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:   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).

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Install the crankshaft sprocket.   Clean the component mating faces.   Install the crankshaft sprocket key.

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

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Install the LH primary timing chain tensioner guides.   Tighten the bolts to 12 Nm (9 lb.ft).

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: 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 a 3 mm (0.125 in) diameter rod, retain the chain tensioner piston.   Tighten the bolts to 12 Nm (9 lb.ft).   Remove the retaining rod.

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: Make sure that new bolts are installed. :   Install new O-ring seals. Install the LH VCT control solenoid housing.   Install the O-ring seals.   Tighten the bolts to 22 Nm (16 lb.ft).   Tighten the nut to 10 Nm (7 lb.ft).

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

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

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: 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 a 3 mm (0.125 in) diameter rod, retain the chain tensioner piston.   Tighten the bolts to 12 Nm (9 lb.ft).   Remove the retaining rod.

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: Make sure that new bolts are installed. :   Install new O-ring seals. Install the RH VCT control solenoid housing.   Install the O-ring seals.   Tighten the bolts to 22 Nm (16 lb.ft).   Tighten the nut to 10 Nm (7 lb.ft).

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Remove the special tool from the RH cylinder head.

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Remove the special tool from the LH cylinder head.

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Install the oil pan extension.   Clean the component mating faces.   Apply a 3 mm (0.125 in) diameter bead of sealant, to the area indicated.   Install the bolts, but do not tighten fully at this stage.

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

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Remove the special tool.   Remove the bolt.

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Install the CKP sensor.   Tighten the bolt to 8 Nm (6 lb.ft)

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:   Install a new O-ring seal. Install the halfshaft support bearing housing.   Install the O-ring seal.   Lubricate the O-ring seal with a suitable lubricant.   Tighten the bolts evenly to 25 Nm (18 lb.ft).

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Attach the wiring harness to the LH side of the engine   Secure the clips.

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Attach the wiring harness to the RH side of the engine.   Secure the clips.

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Install the power steering pump mounting bracket.   Tighten the bolts to 25 Nm (18 lb.ft).

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:   Install a new gasket. :   Install a new O-ring seal. Install the engine front cover.   Clean the component mating faces.   Apply a 3 mm (0.125 in) diameter bead of sealant 12mm (0.5 in) long, to the 8 places indicated.   Install the gasket.   Install the O-ring seal.

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

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

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:   Install new seals. Install the LH valve cover plug aperture seals.

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:   Install a new gasket. :   Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3 mm (0.125 in) diameter 12 mm (0.5 in) 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 LH valve cover.   Clean the component mating faces.   Install the valve cover gasket.

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Install the LH valve cover bolts.   Install the LH valve cover bolts to the positions previously noted.   Tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).

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Connect the LH VCT oil solenoid electrical connector.

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Attach the engine wiring harness to the retaining bracket.

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:   Install a new O-ring seal. With assistance, install the oil level indicator and tube.   Clean the component mating faces.   Install the O-ring seal.   Lubricate the O-ring seal with clean engine oil.   Tighten the nut to 6 Nm (4 lb.ft).

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:   Install new O-ring seals. Install the 4 LH ignition coil-on-plugs.   Install the O-ring seals.   Install the 4 ignition coil-on-plugs.   Tighten the bolts to 6 Nm (4 lb.ft).

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Connect the 4 electrical connectors.

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Install the LH ignition coil-on-plug cover.

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:   Install new seals. Install new RH valve cover plug aperture seals.

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:   Install a new gasket. :   Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3 mm (0.125 in) diameter 12 mm (0.5 in) 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 RH valve cover.   Clean the component mating faces.   Install the gasket.

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Install the RH valve cover bolts.   Install the RH valve cover bolts to the positons previously noted.   Tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).

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:   Install new O-ring seals. Install the 4 RH ignition coil-on-plugs.   Install the O-ring seals.   Install the 4 ignition coil-on-plugs.   Tighten the bolts to 6 Nm (4 lb.ft).

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Connect the 4 electrical connectors.

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Connect the RH VCT oil solenoid electrical connector.

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Attach the engine wiring harness to the retaining bracket.

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Connect the PCV line to the RH valve cover.

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Clean the crankshaft pulley mating faces.

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Using the special tool, install the crankshaft front seal.   Lubricate the seal with clean engine oil.   Use the discarded crankshaft bolt with the special tool.   Remove the special tools.

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

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Install the crankshaft pulley locking ring.

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: 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.

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: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft. Using the special tools, tighten the crankshaft pulley bolt.   Tighten the crankshaft pulley bolt to 380 Nm (280 lb.ft).   Remove the special tools.

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Install the generator mounting bracket.   Tighten the 4 bolts to 45 Nm (33 lb.ft).

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Install the generator.   Tighten the 3 bolts to 48 Nm (35 lb.ft).   Connect the electrical connector.

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Connect the battery positive cable.   Tighten the nut to 10 Nm (7 lb.ft).   Install the battery positive cable cover.

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Install the exhaust manifold heat shield.   Tighten the 2 bolts.

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Install the accessory drive belt idler pulleys.   Tighten the bolts to 25 Nm (18 lb.ft).

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

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:   Install new O-ring seals. Install the coolant manifold.   Clean the components.   Install the O-ring seals.   Connect the 4 coolant hoses and install the clips.   Attach the wiring harness bracket.   Tighten the Torx screws to 10 Nm (7 lb.ft).

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Connect the ECT sensor electrical connector.

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Install the cooling fan drive belt tensioner.   Tighten the bolt to 40 Nm (30 lb.ft).

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Install the A/C compressor mounting bracket.   Tighten the bolts to 25 Nm (18 lb.ft).

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Remove the engine from the engine stand.

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Install the engine.

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Connect the battery ground cable.