Part 1 of 2
ENGINE DISASSEMBLY AND ASSEMBLY-2.3LAssembly 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 at top dead center.
2. Remove the plug bolt.
3. Install the Engine Timing Peg ST 303-507.
Note:
^ Clean the oil pump 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.
^ Stage 1: Tighten the bolts to 10 Nm (1.0 kgf-cm, 80 inch lbs.).
^ Stage 2: Tight the bolts to 23 Nm (2.3 kgf-cm, 17 ft. lbs.).
Note:
^ Clean the oil pump pickup tube 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. Install the rear main oil seal and tighten in the sequence shown.
Caution:
^ Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Note:
^ Clean the gasket surface with metal surface cleaner.
Note:
^ If the oil pan is not secured within four minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow these procedures can cause future oil leakage.
7. Apply a 2.5 mm bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the bolts in the sequence shown.
8. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
9. Clean the cylinder head gasket surface with metal surface cleaner.
10. Apply silicone gasket and sealant to the locations shown.
11. Install a new cylinder head gasket.
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.
12. Install the cylinder head. Tighten the bolts in the sequence shown in five stage.
^ Stage 1: Tighten the bolts to 5 Nm (0.5 kgf-cm, 44 inch lbs.).
^ Stage 2: Tighten the bolts to 15 Nm (1.5 kgf-cm, 11 ft. lbs.).
^ Stage 3: tighten the bolts to 45 Nm (4.5 kgf-cm, 33 ft. lbs.).
^ Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
^ 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.
13. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
^ Stage 2: Tighten the bolts to 7 Nm (0.7 kgf-cm, 62 inch lbs.).
^ Stage 3: Tighten the bolts to 16 Nm (1.6 kgf-cm, 12 ft. lbs.).
14. Install the oil pump chain and sprockets.
^ The crankshaft sprocket flange must be facing away from the engine block.
Note:
^ The oil pump chain sprocket must be held in place.
15. Tighten the oil pump sprocket bolt.
16. Install the oil pump chain guide and the shoulder bolt.
17. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
Note:
^ Sprockets must turn freely on the camshafts.
18. 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.
19. Using the edge of a vise, compress the timing chain tensioner plunger.
20. Using a small pick, push back and hold the ratchet mechanism.
21. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
22. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
23. Install the timing chain.
24. Install the timing chain guides.
25. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
26. 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.
27. Tighten the camshaft sprocket bolts.
28. Clean the front cover gasket surface with metal surface cleaner.
29. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
30. 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.
31. Install the front cover. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the 8 mm bolts to 10 Nm (1.0 kgf-cm, 89 inch lbs.).
^ Stage 2: Tighten the 10 mm bolts to 25 Nm (2.5 kgf-cm, 18 ft. lbs.).
^ Stage 3: Tighten the 13 mm bolts to 48 Nm (4.8 kgf-cm, 35 ft. lbs.).
Note:
^ Do not reuse the crankshaft pulley bolt and washer.
32. Install the vibration damper.
Note:
^ Rotate the vibration damper as necessary to align.
1. Install the vibration damper.
2. Install the timing pin bolt through the vibration damper and into the front cover.
3. Install the vibration damper bolt. Tighten the bolt in two stages.
- Stage 1: Tighten the bolt to 40 Nm (4.0 kgf-cm, 30 ft. lbs.).
- Stage 2: Tighten the bolt and additional 90 degrees (1/4 turn).
^ Remove the timing pin bolt.
33. Remove the special tool from the side plug access hole.
34. Install the side plug.
35. Using the special tool, install a new crankshaft position (CKP) sensor. The tool must engage a tooth of the vibration damper.
36. Remove the special tool.
37. Clean the valve cover gasket surface with metal surface cleaner.
38. 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.
39. Install the valve cover and tighten the bolts in the sequence shown.
40. 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 clean coolant prior to assembly.