:  Jun 30, 2008





















































. Disconnect the battery ground cable.

.
  : 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.

. Remove the engine.

. Mount the engine to an engine stand.

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




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




. 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.




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




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




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

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




. Remove the generator mounting bracket.
  Remove the 4 bolts.




. Disconnect the engine oil temperature sensor electrical connector.



. Disconnect the engine oil pressure (EOP) sensor electrical connector.

. :
  Some oil spillage is inevitable during this operation.

:
  Clean the components general area prior to dismantling.

Remove the oil filter.



. Remove the oil filter housing.
  Remove the 3 bolts.
  Remove and discard the O-ring seal.




.
  : 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.



. :
  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.

. :
  The crankshaft pulley will be very tight.

Using the special tools, remove the crankshaft pulley.
  Collect the locking ring.
  Remove the special tools.




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



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




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



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




. Remove the remaining ignition coil-on-plugs.

. Disconnect the positive crankcase ventilation (PCV) line.



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

. Disconnect the valve cover breather hose.



. Release the engine wiring harness from the retaining bracket.



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



. :
  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.




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




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




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



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




. Remove the remaining LH ignition coil-on-plugs.

. 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.




. Release the engine wiring harness from the retaining bracket.



. :
  Note the fitted position of the retaining bolts prior to removal.

Remove the LH valve cover.
  Remove the 14 valve cover retaining bolts.




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




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




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




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




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




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




. Disconnect the crankshaft position (CKP) sensor electrical connector.



. Remove the CKP sensor.
  Remove the bolt.




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

Lock the crankshaft.
  Install the special tool.
  Install the screw.




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




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




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




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




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




. Remove the RH primary timing chain.



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




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




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




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




. Remove the LH primary timing chain.



. :
  Note the orientation of the crankshaft sprocket.

Remove the crankshaft sprocket.
  Remove the crankshaft sprocket key.




. Remove the special tool.



.
  : The bolts can only be used 3 times, mark the bolts with a center punch. If 2 punch marks are visible, discard the bolts.

Remove the torque converter flexplate.
  Remove the 8 bolts.




.
  : Note the position of the bolts, prior to removal.

Remove the oil pan.
  Remove the 17 bolts.
  Remove and discard the gasket.




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




. Remove the oil pan extension.
  Remove the 18 bolts.




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




. Remove the baffle plate.
  Remove the 6 bolts.




.
  : 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.

:
  If the crankshaft main bearing carrier retaining bolts have been marked with a center punch dot, they must be discarded and new bolts installed.

Remove the crankshaft main bearing carrier.
  Remove the crankshaft main bearing carrier retaining bolts in the indicated sequence.




. Remove and discard the rear crankshaft oil seal.



.
  : Use only a plastic scraper when removing the sealing material.

  : If any new bolts are to be installed to retain the crankshaft main bearing carrier, pre-stress the retaining bolts by installing the crankshaft main bearing carrier without any sealant and tightening the new retaining bolts to the specified torque. Remove the crankshaft main bearing carrier once the bolts have been pre-stressed. Failure to follow this instruction may result in damage to the vehicle.

Clean all the mating faces and reusable parts thoroughly and check for damage.

. :
  Install the crankshaft main bearing carrier and tighten bolts to specification within twenty minutes of applying the sealant.

Apply a 2 mm (0.08in) bead of sealant to the cylinder block in the area shown.
  Use WSS-M4G323-A4-RTV sealant.




. :
  Install the crankshaft main bearing carrier and tighten bolts to specification within twenty minutes of applying the sealant.

Apply a 1 mm (0.039in) bead of sealant to the cylinder block in the area shown.
  Use WSS-M4G323-A4-RTV sealant.




.
  : Make sure all dowels are fully seated into the crankshaft main bearing carrier prior to tightening the bolts.

:
  Do not lubricate the crankshaft main bearing carrier retaining bolts.

:
  Do not rotate the crankshaft until all the retaining bolts are tightened to specification.

:
  The retaining bolts must be tightened within twenty minutes of applying the sealant.

:
  Tighten the retaining bolts in the sequence shown.

Install the crankshaft main bearing carrier to the cylinder block.
  1) Stage 1: Bolts 21 to 32, tighten to 15 Nm (11 lb.ft).
  2) Stage 2: Bolts 33 to 34, tighten to 15 Nm (11 lb.ft).
  3) Stage 3: Bolts 1 to 10, tighten to 25 Nm (18 lb.ft).
  4) Stage 4: Bolts 11 to 20, tighten to 15 Nm (11 lb.ft).
  5) Stage 5: Bolts 1 to 10, tighten to 35 Nm (26 lb.ft), then a further 135 degrees.
  6) Stage 6: Bolts 11 to 20, tighten to 20 Nm (15 lb.ft), then a further 150 degrees.
  7) Stage 7: Bolts 21 to 32, tighten to 20 Nm (15 lb.ft), then a further 90 degrees.
  8) Stage 8: Bolts 33 to 34, tighten to 20 Nm (15 lb.ft), then a further 150 degrees.
  9) Stage 9: Center punch each of the bolt heads to indicate it has been reused.




. Remove the special tool.



. Remove the special tool from the left-hand cylinder head.



. Remove the special tool from the right-hand cylinder head.



.
  : Make sure that number 1 cylinder intake camshaft lobes are vertical to the cylinder head face.

Position the right-hand camshafts to the neutral position.



.
  : Make sure that number 2 cylinder exhaust camshaft lobes are vertical to the cylinder head face.

Position the left-hand camshafts to the neutral position.



.
  : Make sure no binding of the crankshaft occurs.

  : Make sure the spark plugs are removed to enable the engine to rotate freely.

Carefully rotate the crankshaft two complete turns to check for correct operation.

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




. :
  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.




.
  : Alternate the nut tightening to correctly seat the crankshaft rear oil seal.

Using the special tool, install the rear crankshaft oil seal.



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

Remove the special tool.



. :
  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).




.
  : Make sure the spark plugs are removed to enable the engine to rotate freely.

  : Do not rotate the crankshaft counterclockwise.

  : Rotate the crankshaft clockwise to position the engine to top dead center (TDC) No. 1 cylinder

Install the special tool.



. Install the special tool to the left-hand cylinder head.



. Install the special tool to the right-hand cylinder head.



. :
  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).

. :
  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).

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

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

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

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




.
  : 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).

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

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

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




.
  : 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).

. Remove the special tool from the RH cylinder head.



. Remove the special tool from the LH cylinder head.



. Install the oil pan extension.
  Clean the component mating faces.
  Apply a 3 mm (0.118 in) diameter bead of sealant, to the area indicated.
  Install the bolts, but do not tighten fully at this stage.




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



. Remove the special tool.
  Remove the bolt.




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

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




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




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

. :
  Install a new gasket.

:
  Install a new O-ring seal.

Install the engine front cover.
  Clean the component mating faces.
  Apply a 3 mm (0.118 in) diameter bead of sealant 12mm (0.47 in) long, to the 8 places indicated.
  Install the gasket.
  Install the O-ring seal.




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



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

. :
  Install new seals.

Install the LH valve cover plug aperture seals.

. :
  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 (0.118 in) diameter 12 mm (0.47 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.




. 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).




. Connect the LH VCT oil solenoid electrical connector.

. Attach the engine wiring harness to the retaining bracket.

. :
  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).

. :
  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).

. Connect the 4 electrical connectors.



. Install the LH ignition coil-on-plug cover.

. :
  Install new seals.

Install new RH valve cover plug aperture seals.

. :
  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 (0.118 in) diameter 12 mm (0.47 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.




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




. :
  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).

. Connect the 4 electrical connectors.



. Connect the RH VCT oil solenoid electrical connector.

. Attach the engine wiring harness to the retaining bracket.

. Connect the PCV line to the RH valve cover.

. Clean the crankshaft pulley mating faces.

. 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.




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

. Install the crankshaft pulley locking ring.

.
  : 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.

.
  : 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.




. Install the oil filter housing.
  Clean the component mating faces.
  Install a new O-ring seal.
  Tighten the bolts to 20 Nm (15 lb.ft).

. Install the engine oil filter.
  Lubricate the oil filter seal with clean engine oil and tighten to 18 Nm (13 lb.ft).

. Connect the EOP sensor electrical connector.

. Connect the engine oil temperature sensor electrical connector.

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

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

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

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

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

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

. :
  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).

. Connect the ECT sensor electrical connector.

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

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

. Remove the engine from the engine stand.

. Install the engine.

. Connect the battery ground cable.