- With the crankshaft and bearings in place, plastic gage all bearing clearances. Refer to «Crankshaft and Bearings Cleaning and Inspection»(ref-196120-S04894967812005100600000) .
- Inspect the crankshaft end play with the crankshaft bearings installed.
- Inspect for permissible crankshaft end play. Refer to «Crankshaft and Bearings Cleaning and Inspection»(ref-196120-S04894967812005100600000) .
- With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft bearings and the middle crankshaft journal for permissible out-of-round runout. Refer to «Engine Mechanical Specifications»(ref-196120-S06616188492005100600000) .
- Coat the crankshaft bearings with engine oil.
- Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
- Install the crankshaft bearings in he engine block.
- Install the crankshaft.
- Install the crankshaft bearings to the crankshaft bearing caps.
- Install the crankshaft bearing caps.
- Install the new crankshaft bearing bolt. Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb ft). Using the J 45059 or the KM-470-B , tighten the crankshaft bearing cap bolts another 45 degrees.
- Install the upper connecting rod bearings to the connecting rods.
- Install the lower connecting rod bearings to the connecting rod bearing caps.
- Install the connecting rod bearing caps to the connecting rods.
- Install the new connecting rod bearing cap bolts. Tighten: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Using the J 45059 or the KM-470-B , tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees.
- Install the oil pump.
- Install the oil pump retaining bolts (1). Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb in).
- Install the oil pump pickup tube.
- Install the oil pump pickup tube bolts. Tighten: Tighten the oil pump/pickup tube bolts to 10 N.m (89 lb in).
- Install the oil pan gasket to the oil pan.
- Install the oil pan.
- Install the oil pan retaining bolts. Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 lb in).
- Rotate the engine on the OTC 1726 .
- Install the rear timing belt cover.
- Install the rear timing belt cover bolts. Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 lb in).
- Install the crankshaft timing belt gear.
- Install the timing belt automatic tensioner.
- Install the timing belt automatic tensioner bolts. Tighten: Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb ft).
- Install the timing belt idler pulley.
- Install the timing belt idler pulley bolt. Tighten: Tighten the timing belt idler pulley bolt to 40 N.m (30 lb ft).
- Install the intake camshaft gear.
- Install the intake camshaft gear bolt while holding the intake camshaft firmly in place. Tighten: Tighten the intake camshaft gear bolt to 67.5 N.m (49 lb ft).
- Install the exhaust camshaft gear.
- Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place. Tighten: Tighten the exhaust camshaft bolt to 67.5 N.m (49 lb ft).
- Install the timing belt. Refer to «Timing Belt Replacement»(ref-196120-S41628167902005100600000) .
- Adjust the timing belt tension. Refer to «Timing Belt Inspection»(ref-196120-S36498711682005100600000) .
- Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear valve cover-to-cylinder head seal.
- Install the valve cover and the valve cover gasket.
- Install the valve cover washers.
- Install the valve cover nuts. Tighten: Tighten the valve cover nuts to 9 N.m (80 lb in).
- Connect the ignition wires to the spark plugs.
- Install the engine cover.
- Install the engine cover bolts. Tighten: Tighten the engine cover bolts to 3 N.m (27 lb in).
- Connect the crankcase ventilation tube to the valve cover.
- Install the upper and lower front timing belt cover.
- Install the upper and lower front timing belt cover bolts. Tighten: Tighten the upper and lower front timing belt cover bolts to 10 N.m (89 lb in).
- Install the power steering pump, if equipped.
- Install the power steering pump mounting bolts. Tighten: Tighten the power steering pump mounting bolts to 25 N.m (18 lb in).
- Install the engine lifting device.
- Remove the engine from the OTC 1726 .
- Install a new crankshaft rear oil seal using the J 36972 (1) or KM-635 .
- Install the flywheel.
- Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 35 N.m (25 lb ft). Use the J 45059 or KM-470-B to tighten the flywheel bolts 30 degrees plus 15 degrees. For the manual transaxle, tighten the flexible plate bolts to 60 N.m (44 lb ft).
- Install the engine. Refer to «Engine Replacement»(ref-196120-S15857445762005100600000) .
Contents
Wiring diagrams Section: Mechanical- Fastener Tightening Specifications
- Engine Mechanical Specifications
- Diagnostic Starting Point - Engine Mechanical
- Strategy Based Diagnostics
- Visual/physical Inspection
- Intermittent
- Symptom List
- Oil Pressure Diagnosis and Testing
- Oil Leak Diagnosis
- Black Light and Dye Method
- Repairing the Leak
- Definition for Knock
- Engine Knocks Cold and Continues for Two-Three Minutes And/or Knock Increases with Engine Torque
- Engine Noise Under Load
- Light Knock Hot
- Engine Noise on Start-Up, but Only Lasting a Few Seconds
- Knocks at Idle Hot
- Main Bearing Noise
- Connecting Rod Bearing Noise Symptom
- Piston Noises
- Base Engine Misfire with Abnormal Valve Train Noise
- Engine Compression Test
- Tools Required
- Removal Procedure
- Installation Procedure
- Adjustment Procedure
- Timing Belt Replacement
- Cylinder Head Replacement
- Oil Pump Cleaning and Inspection
- Exhaust Manifold Removal
- Exhaust Manifold Installation
- Crankshaft and Bearings Cleaning and Inspection
- Piston, Connecting Rod, and Bearings Cleaning and Inspection
- Piston Inspection
- Connecting Rod Bearing Inspection
- Piston, Connecting Rod, and Bearing Replacement
- Valve Rocker Arms Cleaning and Inspection
- Cleaning Procedure
- Cylinder Head Disassemble
- Disassembly Procedure
- Valve Guide Reaming/valve and Seat Grinding
- Valve Grind-In
- Valve Grind
- Valve Guide - Ream
- Valve Seat - Cut
- Cylinder Head Cleaning and Inspection
- Cylinder Head Assemble
- Crankshaft Replacement
- Cylinder Head and Gasket
- Crankshaft
- Timing Belt
- Oil Pump
- Oil Pan
- Exhaust Manifold
- Intake Manifold
- Camshafts
- Exhaust Gas Recirculation (EGR) Valve
- Cleanliness and Care
- Special Tools
- Abbreviations
- Airbag
- Anti-Lock/traction Control
- Automatic HVAC System
- Automatic Trans
- Axle Shafts
- Basic Trouble Shooting
- Body Electrical
- Brakes
- Cabin Air Filter
- Charging System
- Check Lists
- Clutches Manual & Hydraulic
- Communication Devices
- Cooling System (Mechanical)
- Diagnostic Connector Locations
- Door Locks & Anti-Theft Systems
- Drive Cycles
- Driveline/axles
- DTC Index
- Electrical
- Electrical Component Locations
- Emission Applications
- Engine
- Engine Performance
- Entertainment Systems
- Exhaust
- Exterior Body Panels
- Exterior Lights
- Exterior/interior Trim
- Frames, Subframes & Crossmembers
- Fuses & Circuit Breakers
- Gauges & Instrument Panels
- Heated Glass/defoggers
- Hoist/jack
- Horns
- Identification
- Ignition Switch/steering Lock
- Lubrication System
- Manual & Power Steering
- Manual HVAC System
- Manual Trans
- MAP Guidelines
- Mechanical
- Mechanical - Hydraulic
- Metric Conversions
- Mode 6
- Oem General Information
- Paint/coatings
- Parking Brake System
- Reset Procedures
- Restraints Control Systems
- Seats
- Specifications
- Steering
- Sun Roof/t-Top/convertible Top
- Suspension Front
- Suspension Rear
- Testing & Diagnostics
- Timing Belt
- Traction Control Disable
- Transmission
- Wheel & Tire System
- Wheel Alignment
- Wiper/washer Systems