Part 2

ENGINE ASSEMBLY - 2.5L

NOTE:Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE:Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
17. Install and tighten the 10 new main bearing beam bolts.

- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm {0.5 kgf-m, 44 in-lbf}.
- Stage 2: Tighten to 25 Nm {2.5 kgf-m, 18 in-lbf}.
- Stage 3: Tighten an additional 90 degrees.





18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.

- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.





CAUTION:Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE:Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE:Make sure the piston arrow on top is facing toward the front of the engine.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.

- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.





20. Install the connecting rod caps and the new bolts.

- Tighten the bolts in 2 stages.

- Stage 2: Tighten to 29 Nm {2.9 kgf-m, 21 in-lbf}.
- Stage 2: Tighten an additional 90 degrees.





21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).

NOTE:Due to the precision interior construction of the balancer unit, it should not be disassembled.
NOTE:The original adjustment shims must be installed in their original positions.
NOTE:Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
22. Install the adjustment shims in their original positions on the seat faces of the balancer unit.





23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.





24. Install the balancer unit bolts.

- Tighten in the sequence shown in 2 stages.

- Stage 1: Tighten to 25 Nm {2.5 kgf-m, 18 in-lbf}.
- Stage 2: Tighten to 50 Nm {5.1 kgf-m, 37 ft-lbf}.





25. Remove the Crankshaft TDC Timing Peg.

26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.





27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg

- Remove the Crankshaft TDC Timing Peg.





NOTE:Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
NOTE:The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
NOTE:For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.
28. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.

- Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
- Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
- Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).

CAUTION:Failure to position the No. 1 piston at Top Dead Center can result in damage to the engine. Turn the engine in the normal direction of rotation only.
29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).





NOTE:The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
30. Install the Crankshaft TDC Timing Peg.





31. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages:

- Stage 1: Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Stage 2: Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.





32. Install a new oil pump pickup tube gasket and the pickup tube.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





33. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.





34. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

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 traces of sealant.
35. Clean and inspect all mating surfaces.





NOTE:If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
36. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.





37. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.





38. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.





39. Install the cylinder head alignment dowels.

- Dowels must be fully seated in the cylinder block.

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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE:Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE:If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
40. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
a. Remove any large deposits of silicone or gasket material with a plastic scraper.

b. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

c. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

d. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.





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





42. Install a new head gasket.





NOTE:The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE:Lubricate the bolts with clean engine oil prior to installation.
43. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:

- Stage 1: Tighten to 5 Nm {0.5 kgf-m, 44 in-lbf}.
- Stage 2: Tighten to 15 Nm {1.5 kgf-m, 133 in-lbf}.
- Stage 3: Tighten to 45 Nm {4.6 kgf-m, 33 ft-lbf}.
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.

NOTE:Coat the valve tappets with clean engine oil prior to installation.
44. Install the valve tappets.





CAUTION:Install the camshafts with the alignment slots in the camshafts 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 when the timing chain is removed, 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.
45. Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing caps in the sequence shown in 3 stages:

- Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger-tight.
- Stage 2: Tighten to 7 Nm {0.7 kgf-m, 62 in-lbf}.
- Stage 3: Tighten to 16 Nm {1.6 kgf-m, 142 in-lbf}.





46. Install the Variable Camshaft Timing (VCT) system oil filter and the plug in the intake camshaft thrust cap.

- Tighten to 17 Nm {1.7 kgf-m, 150 in-lbf}.





47. Install the VCT solenoid and the bolt.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





NOTE:Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
48. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.

- The crankshaft sprocket flange must be facing away from the engine block.





49. Install the oil pump chain, sprocket and bolt.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.





50. Install the oil pump chain tensioner shoulder bolt.

- Stage 1: Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





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

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





CAUTION:The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
52. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.





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





54. Install the LH timing chain guide and the bolts.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





55. Install the timing chain.





56. Install the RH timing chain guide.





CAUTION:Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE:If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
57. Using the edge of a vise, compress the timing chain tensioner plunger.





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





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





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





61. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.





NOTE:The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.

- Tighten to 72 Nm {7.3 kgf-m, 53 ft-lbf}.

CAUTION:Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
63. Clean and inspect the mounting surfaces of the engine and the front cover.





NOTE:The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
64. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.





65. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:

- Tighten the 8-mm bolts to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Tighten the 13-mm bolts to 48 Nm {4.9 kgf-m, 35 ft-lbf}.





NOTE:Remove the through-bolt from the Camshaft Front Oil Seal Installer.
NOTE:Lubricate the oil seal with clean engine oil.
66. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.





NOTE:Do not install the crankshaft pulley bolt at this time.
NOTE:Apply clean engine oil on the seal area before installing.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





CAUTION:Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
NOTE:This step will correctly align the crankshaft pulley to the crankshaft.
68. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.





CAUTION:The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
NOTE:Do not reuse the crankshaft pulley bolt.
69. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

- Stage 1: Tighten to 100 Nm {10.2 kgf-m, 74 ft-lbf}.
- Stage 2: Tighten an additional 90 degrees (1/4 turn).





70. Remove the 6 mm x 18 mm bolt.





71. Remove the Crankshaft TDC Timing Peg.





NOTE:Only turn the engine in the normal direction of rotation.
72. Remove the Camshaft Alignment Plate.

73. Turn the crankshaft clockwise one and three-fourths turns.





74. Install the Crankshaft TDC Timing Peg





NOTE:Only turn the engine in the normal direction of rotation.
75. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.