Engine

Special Tool(s)

1. Check the cylinder bore taper.
2. Check the cylinder out of round.
3. WARNING: Eye protection is required to be worn during use of compressed air. Failure to follow these instructions could result in possible personal injury.

Clean and dry the cylinder block.

• Clean gasket material, dirt and debris from the cylinder block.
• Wash the cylinder block with a suitable soap and water solution.
• Dry the cylinder block completely using compressed air.

4. Install the upper crankshaft main bearings, the upper crankshaft thrust main bearing and the lower crankshaft main bearings.

5. Position the crankshaft.

6. Check the crankshaft main bearing journal clearance.
7. Apply a light coat of clean engine oil to the crankshaft bearings and journals.
8. CAUTION: Make sure the main bearing caps are installed in their original position or engine damage may occur.

Install the main bearing caps.

9. Loosely install the bolts.

10. Tighten the bolts in the sequence shown.

11. NOTE: Do not remove the wedge until the crankshaft main bearing thrust cap bolts are tightened.

Wedge the crankshaft forward to fully seat the crankshaft thrust main bearings, while prying the crankshaft main bearing thrust cap to the rear.

12. Tighten the bolts.

13. Install the crankshaft key.

14. Rotate the crankshaft and inspect for excessive drag or binding.

15. Clean and inspect the pistons.
16. Inspect the crankshaft end play.
17. Check the piston-to-cylinder bore clearance.
18. Check the piston ring clearance.
19. NOTE: Lubricate the piston rings with clean engine oil.

Install the piston rings.

• Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

20. CAUTION: PIP mark on pistons and squirt groove on connecting rods must be located on the intake side of the engine or possible engine damage may occur.

CAUTION: Use care when installing piston and connecting rod assemblies. Do not scratch the cylinder walls or the crankshaft journals or engine damage may occur.

CAUTION: The arrow on the piston must point toward the front of the engine or engine damage may occur.

NOTE: Lubricate the cylinder block, piston rings and connecting rod prior to installation with super premium motor oil or equivalent.

Using the special tools, install the four pistons and connecting rod assemblies.

21. CAUTION: Connecting rods and connecting rod caps must be correctly oriented, with interlocking tangs on same side of connecting rod or possible engine damage may occur.

NOTE: Rotate the crankshaft after installing each connecting rod cap and inspect for excess drag or binding.

Fit the connecting rod bearing.

• Install the four upper and the four lower connecting rod bearings.
• Inspect the connecting rod bearing-to-crankshaft clearance.

22. NOTE: Lubricate the connecting rod bearings and the crankshaft journals prior to final installation of the bearing caps with super premium motor oil or equivalent.

Install the four connecting rod caps.

• Install the new bolts and tighten in two stages:
• Tighten to 35 Nm (26 ft. lbs.).
• Tighten an additional 90 degrees.

23. NOTE: The clearance between the lower cylinder block sealing surfaces on the crankshaft rear oil seal retainer and the crankshaft cannot exceed 0.2 - 0.8 mm (0.008 - 0.031 inch).

Install the crankshaft rear oil seal retainer.

• Install the new crankshaft rear oil seal retainer gasket.
• Install the crankshaft rear oil seal retainer.
• Install the bolts.

24. NOTE: The clearance between the lower cylinder block sealing surfaces on the oil pump and the cylinder block cannot exceed 0.3-0.8 mm (0.12-0.31 inch)

Install the oil pump.

• Install the new oil pump gasket.
• Install the oil pump.

25. If equipped, install the new pipe plugs and alignment dowels.

• Transfer the bracket and manifold mounting studs as necessary.

26. Use the Oil Pump Seal Replacer to install a new crankshaft front seal.

27. CAUTION: The cylinder block cradle must be installed and the bolts tightened to specification within four minutes of sealant application or possible leakage may occur.

NOTE: Apply a 3 mm (0.1 inch) bead of silicone gasket and sealant in four places where the oil seal retainers meet the cylinder block.

Install a gasket and the cylinder block cradle. Tighten the bolts in two steps in the sequence shown.

• Tighten the bolts to 7 - 13 Nm (62 - 115 inch lbs.).
• Tighten the bolts to 20 - 24 Nm (15 - 17 ft. lbs.).

28. Install the oil pump cover and screen.

• Install new oil pump inlet tube gasket.
• Install the oil pump cover and screen.

29. NOTE: The oil pan must be installed and the bolts tightened to specification within four minutes of sealant application.

Apply a 3 mm (0.1 inch) bead of silicone gasket and sealant.

30. Install the oil pan. Tighten the bolts in the sequence shown.

31. Install the coolant pump housing.

32. CAUTION: The bolts are torque-to-yield, new bolts must be installed or engine damage may occur.

Tighten the bolts in three steps in the sequence shown.

• Tighten the bolts to 15 - 25 Nm (12 - 18 ft. lbs.).
• Tighten the bolts to 35 - 45 Nm (26 - 33 ft. lbs.).
• Tighten the bolts an additional 105 degrees.

33. Install the timing cover backplate.

34. NOTE: Install the timing belt idler pulley.

35. NOTE: Lubricate the valve tappets prior to installation with clean engine oil.

NOTE: If valve tappets are being reused the valve tappet must be installed in its original position or engine damage may occur.

Install valve tappets in their original position as marked during disassembly.

36. NOTE: Use your thumb to press the locating pins on the gasket into the holes.

Press a new gasket into the oil feed flange.

37. Install the oil control solenoid and bushing on the exhaust camshaft.

38. CAUTION: The cylinder head front camshaft journal thrust cap must be installed first to correctly position the camshaft in the cylinder head.

CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to be sure they are assembled in their original positions. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.

NOTE: Apply a bead of gasket maker to the sealing surfaces of the front camshaft journal thrust cap prior to installation.

NOTE: Lubricate the camshaft bearing surfaces with clean engine oil prior to assembly.

Install the camshafts

• Position the camshafts and camshaft journal caps.
• Install the bolts and tighten the bolts in several two-turn passes using the sequence shown.

39. NOTE: Measure each valve's clearance at base circle before removing the camshafts. The shims are not serviceable with the camshafts in place. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time.

Use a feeler gauge to measure each valve's clearance and record its location.

40. NOTE: The corrected shims allow the following valve clearances:

• intake valve clearance - 0.11-0.18 mm ( in)
• exhaust valve clearance - 0.27-0.34 mm (0.0106-0.0134 in)

NOTE: A midrange clearance is the most desirable:

• intake: 0.15 mm (0.006 in)
• exhaust: 0.3 mm (0.012 in)

NOTE: Select shims using this formula: shim thickness = measured clearance plus (+) the base shim thickness minus (-) most desirable thickness.

NOTE: The shims are marked for thickness; example: 2.22 mm = 222 on shim.

If adjustment is needed, remove the camshafts and tappets.

• Remove the shims on the tappets requiring adjustment and install the correct shims using the formula described above.
• Reinstall the tappets, camshaft, and the camshaft bearing caps as described earlier.
• Recheck the valve clearance and correct as necessary.

41. Rotate the oil control bushing one full turn and inspect for binding. Position the bushing with the single hole in the 12 o'clock position.

42. Install the variable camshaft timing oil feed flange bolts.

• Tighten the bolts in the sequence shown.

43. NOTE: After carrying out the check, position the hole in the 12 o'clock position. Check that the oil feed ring moves freely.

• If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and tighten them again as described in the previous step.

44. NOTE: Exhaust camshaft oil seal shown, intake seal similar. Using the special tool, install new camshaft front oil seals.

45. NOTE: Make sure that the tab on the sprocket engages the hole previously positioned at 12 o'clock in the oil control solenoid bushing. Install the camshaft sprockets and hand-tighten the bolts.

46. NOTE: Installation of the alignment tool into the exhaust camshaft may require the camshaft to be rotated clockwise.

Install the camshaft alignment timing tool on the back of the camshafts.

47. Install the timing belt guide and crankshaft sprocket.

48. NOTE: Cylinder No. 1 is at top dead center (TDC) when the keyway is in the 12 o'clock position.

Position the crankshaft just prior to top dead center.

49. NOTE: Remove the stud bolt.

Install the crankshaft TDC Timing Peg.

50. Rotate the crankshaft clockwise against the peg.

51. Install the timing belt tensioner and a new timing belt.

• Hand-tighten the bolt.

52. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover.

53. Adjust the timing belt tensioner.

1. Using a 6 mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown.
2. Tighten the tensioner pulley bolt.

54. CAUTION: The camshaft must be held stationary on the hexagons with locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.

Tighten the bolt on the intake camshaft sprocket.

55. CAUTION: The camshaft must be held stationary on the hexagons with locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.

Tighten the bolt on the exhaust camshaft sprocket in three stages.

• Stage 1: Tighten the bolt to 50 Nm (36 lb-ft).
• Stage 2: Remove the TDC peg and the camshaft alignment timing tool.
• Stage 3: Tighten the bolt to 115-125 Nm (85-92 lb-ft).

56. NOTE: Turn the engine two turns in the normal direction of rotation by the crankshaft.

Check the valve timing by inserting the special tools and correct the alignment as necessary.

• Screw in special tool 303-574 and make sure that the crankshaft is resting against the special tool.
• Insert special tool 303-465 into the camshafts. If necessary, loosen the timing pulleys and correct the camshaft alignment.
• Remove the special tools.

57. Install the stud bolt.

58. NOTE: If the original spark plugs are being reused, install the spark plugs in their original locations.

Install the four spark plugs.

59. NOTE: Install a new oil plug seal.

Install a new oil plug on the variable camshaft timing assembly.

60. Install the lower timing belt cover.