Reassembly

Assembly Note

Warning: Failure to position the No. 1 piston at TDC can result in damage to the engine.

1. Using the damper bolt, turn the crankshaft clockwise to position the No. 1 piston.

2. Remove the plug bolt.

3. Install the Engine Timing Peg ST303-507.

Note: Clean the gasket surface with metal surface cleaner.

4. Install a new gasket and the oil pump assembly. Tighten the bolts in the sequence shown in two stages.
1. Stage 1: Tighten the bolts to 10 Nm (1.0 kgf-m, 80 inch lbs.).
2. Stage 2: Tight the bolts to 23 Nm (2.3 kgf-m, 17 ft. lbs.).

Note: Clean the gasket surface with a metal surface cleaner.

5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.

6. Using the special tool, install the rear main oil seal.

7. Tighten the rear main oil seal bolts in the sequence shown.

Note: Clean the gasket surface with metal surface cleaner.

8. Install a new gasket and the oil pan. Tighten the bolts in the sequence shown.

9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Note: Clean the gasket surface with metal surface cleaner.

10. Install anew cylinder head gasket.
11. Clean the cylinder head gasket surface with metal surface cleaner.

12. Apply silicone gasket and sealant to the locations shown.

Note: The cylinder head must be secured within four minutes of silicone gasket application. If the cylinder head is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

13. Install the cylinder head. Tighten the bolts in the sequence shown in five stage.
1. Stage 1: Tighten the bolts to 5 Nm (0.5 kgf-m, 44 inch lbs.).
2. Stage 2: Tighten the bolts to 15 Nm (1.5 kgf-m, 11 ft. lbs.).
3. Stage 3: tighten the bolts to 45 Nm (4.5 kgf-m, 33 ft. lbs.).
4. Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).

Caution: Install the camshafts with the alignment notches in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.

Note: Lubricate the camshaft journals and bearing caps with clean engine oil.

14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
1. Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
2. Stage 2: Tighten the bolts to 7 Nm (0.7 kgf-m, 62 inch lbs.).
3. Stage 3: Tighten the bolts to 16 Nm (1.6 kgf-m, 12 ft. lbs.).

15. Install the oil pump chain and sprockets.
1. The crankshaft sprocket flange must be facing away from the engine block.

Note: The oil pump chain sprocket must be held in place.

16. Tighten the oil pump sprocket bolt.

17. Install the oil pump chain guide and the shoulder bolt.

18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.

Note: Sprockets must be turn freely on the camshafts.

19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.

Caution: Do not compress the ratchet assembly. This will damage the ratchet assembly.

20. Using the edge of a vise, compress the timing chain tensioner plunger.

21. Using a small pick, push back and hold the ratchet mechanism.

22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

24. Install the timing chain.

25. Install the timing chain guides.

26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.

27. Install the special tool in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.

Note: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.

28. Tighten the camshaft sprocket bolts.
29. Clean the front cover gasket surface with metal surface cleaner.

30. Apply a 2.5 mm beak of silicone gasket and sealant to the front cover.

31. Apply silicone gasket and sealant to the locations shown.

Note: The front cover must be secured within four minutes of silicone gasket application. If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

32. Install the front cover. Tighten the bolts in the sequence shown in three stages.
1. Stage 1: Tighten the 8 mm bolts to 10 Nm (1.0 kgf-m, 89 ft. lbs.)
2. Stage 2: Tighten the 10 mm bolts to 25 Nm (2.5 kgf-m, 18 ft. lbs.).
3. Stage 3: Tighten the 13 mm bolts to 48 Nm (4.8 kgf-m, 35 ft. lbs.).

Note: Do not reuse the crankshaft pulley bolt.

33. Install the vibration damper.
Install the vibration damper.

Note: Rotate the vibration damper as necessary to align.
1. Install the timing pin bolt through the vibration damper and into the front cover.
2. Install the vibration damper bolt. Tighten the bolt in two stages.
1. Stage 1: Tighten the bolt to 40 Nm (4.0 kgf-m, 30 ft. lbs.).
2. Stage 2: Tighten the bolt and additional 90 degrees (1/4 turn).
3. Remove the timing pin bolt.

34. Remove the special tool from the side plug access hole.

35. Install the side plug.

36. Using the special tool, install the crankshaft position (CKP) sensor. The tool must engage a tooth of the vibration damper.

37. Remove the special tool.
38. Clean the valve cover gasket surface with metal surface cleaner.

39. Apply silicone gasket and sealant to the locations shown.

Note: The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

40. Install the valve cover.
41. Install the following:
^ camshaft Position (CMP) sensor.
^ cylinder head temperature (CHT) sensor.
^ spark plugs.

Note: Clean the water pump gasket surface with metal surface cleaner.

Note: Lubricate the water pump O-ring seal with MERPOL prior to assembly.

42. Install the water pump.

43. Install the water pump pulley.

44. Install the fuel injection supply manifold and the ground strap.

45. Install the left motor mount.

Note: The knock sensor must not touch the engine vent cover.

46. Install the engine vent cover and the knock sensor (KS).

Note: Clean the thermostat housing gasket surface with metal surface cleaner.

47. Install a new gasket and the thermostat housing.

48. Install the bypass hose and the clamp.

49. Install the ignition coil.

Note: Apply silicone dielectric compound to the inside of the spark plug boots.

50. Connect the spark plug wires to the spark plugs.

51. Install the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.

52. Connect the ignition coil and the CHT sensor electrical connectors.

53. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.

54. Install the intake manifold.

55. Attach the vacuum line to the intake manifold. Secure the fuel line clip to the intake manifold.

56. Install the EGR tube.
^ Install the EGR tube bracket to the intake manifold.
^ Connect the EGR tube to the cylinder head.

57. Connect the EGR tube to the intake manifold.

58. Install the engine wiring harness connector bracket.
59. Attach the engine wiring harness pin-type retainers to the intake manifold.

60. Connect the CMP sensor electrical connector and the PCV hose.

61. Connect the following electrical connectors:
^ swirl control valve.
^ knock sensor.
^ electric thermostat.

62. Connect the CKP sensor and wiring pin-type retainers.

63. Connect the swirl control valve electrical connector.

64. Connect the following electrical connectors:
^ manifold absolute pressure (MAP) sensor.
^ throttle position (TP) sensor.
^ idle air control (IAC) valve.

65. Install the power steering pump and reservoir assembly.

Note: Clean the EGR valve gasket surface with metal surface cleaner.

66. Install a new gasket and the EGR valve. Connect the EGR electrical connector.

Note: Clean the water outlet tube gasket surface with metal surface cleaner.

67. Install a new gasket and the water outlet tube.
^ Tighten the bolts.
^ Connect the coolant hose.
^ Connect the engine coolant temperature (ECT) sender electrical connector.