Engine Mechanical - 2.4L: Removal & Installation GMC Terrain I

Installation Procedure

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-491134-S37063866352012073000000) .
2. Remove the right headlamp. Refer to «Headlamp Replacement (Equinox)»(ref-491150-S35344908232012073000000) , «Headlamp Replacement (Terrain)»(ref-491150-S18491521472012073000000) .
3. Install the J-36857 engine rear lift bracket (2).
4. Install the J-36857 engine front lift bracket.
5. Loosen the J-28467-501 engine support fixture adapters adjusting nut.
6. Assemble the J-28467-501 engine support fixture adapters (1) legs to the vehicle and install the J-28467-B universal engine support fixture cross bar and place across the engine compartment.
7. Tighten the adjusting nuts on the J-28467-501 engine support fixture adapters legs until snug, then back the nut off 1/4 turn.
8. From the J-28467-B universal engine support fixture, install the radiator shelf tube J-28467-2A (1) on top of the strut tower tube J-28467-3 (2) above the engine front (right back) lift hook bracket.
9. Install the round tube of the front support assembly J-28467-4A (3) through the large hole in the radiator shelf tube J-28467-2A.
10. Locate the J-28467-4A front support assembly to the upper tie bar.
11. Install the J-28467-9 7/16 inch x 2.0 inch quick-release pin (4) through the top hole in the J-28467-4A front support assembly.
12. Install the J-28467-1A cross bracket assembly (1).
13. Hand tighten the J-28467-1A cross bracket wing nuts (2).
14. Install the J-28467-7A bolt hook through the J-28467-6A bracket.
15. Install the J-28467-34 lift hook wing nut and washer to the J-28467-7A lift hook.
16. Install one of the lift hook and bracket assemblies (1) to the engine support fixture long bar (2).
17. Install the other lift hook and bracket assembly (3) to the J-28467-2A radiator shelf tube (4) above the engine front lift bracket.
18. Install the lift hook J-28467-7A through the engine rear lift bracket.
19. Install the lift hook J-28467-7A (3) through the engine front lift bracket.
20. Hand tighten the lift hook wing nuts J-28467-34 in order to remove all slack from the engine support fixture assembly.

Scheme 9

Oil Level Indicator Tube Replacement

Removal Procedure

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-491134-S37063866352012073000000) .
2. Remove the PCV hose (1) from the camshaft cover.

1. Install the PCV hose (1) to the camshaft cover.
2. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-491134-S37063866352012073000000) .

1. Recover the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-491156-S07584046762012073000000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .
4. Remove the oil fill cap (1).
5. Remove the intake manifold cover (2).
6. Remove the evaporative (EVAP) emission canister valve tube (1) from the intake manifold and reposition.
7. Remove the MAP sensor (3) electrical connector.
8. Remove the throttle body (1). Refer to «Throttle Body Assembly Replacement»(ref-491198-S33054540692012073000000) .
9. Remove the fuel pump cover (3) and insulator (2). Refer to «Fuel Pump Cover Replacement»(ref-491198-S23695830292012073000000) .
10. Disconnect and reposition the low pressure fuel feed pipe from the fuel pump. Refer to «Metal Collar Quick Connect Fitting Service»(ref-491198-S30425081712012073000000) .
11. Remove the fuel rail harness connector bracket bolt (1) and intake manifold insulator bolt.
12. Remove the intake manifold insulator (2).
13. Remove the A/C line nut (1) and line (2) from the compressor and reposition the line to the side.
14. Remove the intake manifold retaining nuts (1), studs (3), and bolts (2).
15. Remove the intake manifold (1).
16. Disconnect electrical connectors as necessary.
17. Transfer parts as necessary.
18. If reusing the intake manifold, clean and inspect as necessary. Refer to «Intake Manifold Cleaning and Inspection (LAF, LEA, or LUK)»(ref-491134-S02587836052012073000000) .

1. Position the intake manifold (4) and hand start the bolts (2).
2. Install the intake manifold studs (3) and tighten to 6 N.m (53 lb in).
3. Tighten the bolts (2) and nuts (1) in sequence to 10 N.m (89 lb in).
4. Install the intake manifold insulator (2).
5. Install the insulator bolt and tighten to 10 N.m (89 lb in).
6. Install the fuel rail harness connector bracket (1) to the intake manifold. Tighten the bracket bolt to 10 N.m (89 lb in).
7. Install new seal washers to the compressor hose. Refer to «Air Conditioning System Seal Replacement»(ref-491156-S32751145912012073000000) .
8. Install the compressor hose (2) to the compressor.
9. Install the compressor hose nut (1) to the compressor and tighten the nut to 22 N.m (16 lb ft).
10. Connect the engine harness electrical connector as necessary.
11. Install the fuel pump insulator (2) and cover (3). Refer to «Fuel Pump Cover Replacement»(ref-491198-S23695830292012073000000) .
12. Install the low pressure fuel pipe assembly (1).
13. Install a new throttle body gasket.
14. Install the throttle body (1). Refer to «Throttle Body Assembly Replacement»(ref-491198-S33054540692012073000000) .
15. Install the EVAP canister valve tube (1).
16. Connect the MAP sensor electrical connector.
17. Install the intake manifold cover (2) onto the camshaft cover ball studs.
18. Install the oil fill cap (1).
19. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-491156-S07584046762012073000000) .
20. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .

Crankshaft Balancer Replacement

Special Tools

1. EN-45059 Angle Meter
2. EN-38122-A Harmonic Balancer Holder

For equivalent regional tools, refer to Special Tools .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-491134-S36357288892012073000000) .
2. Use EN-38122-A holder (1) to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt (2).
3. Remove and discard the crankshaft balancer bolt.
4. Remove the bolt (1), washer (2), and crankshaft balancer (3).

1. Position the crankshaft balancer (3).
2. Install washer (2) and a NEW crankshaft balancer bolt (1).
3. Use the EN-38122-A holder (1) to hold the crankshaft balancer in order to prevent the balancer from rotating while tightening the bolt (2).
4. Tighten the crankshaft balancer bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the EN-45059 meter.
5. Install the drive belt. Refer to «Drive Belt Replacement»(ref-491134-S36357288892012073000000) .

Crankshaft Front Oil Seal Replacement

Special Tools

EN-35268-A Camshaft/Front Main Seal Installer

For equivalent regional tools, refer to Special Tools .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-491134-S07083805762012073000000) .
2. Use a flat-bladed tool to remove the seal from the front cover.

1. Use the EN-35268-A installer in order to install the crankshaft front oil seal to the engine front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-491134-S07083805762012073000000) .

1. Remove the engine mount bracket (1). Refer to «Engine Mount Bracket Replacement»(ref-491134-S35350701452012073000000) .
2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-491134-S16705107472012073000000) .
3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-491134-S07083805762012073000000) .
4. Disconnect the oxygen sensor harness from the front cover and reposition.
5. Remove the engine front cover to water pump bolt (1).
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
7. Remove the engine front cover bolts (1).
8. Remove the engine front cover.
9. Remove and discard the engine front cover gasket (1).

1. Install a NEW engine front cover gasket (1) to the dowel pins.
2. Install the engine front cover.
3. Install the engine front cover bolts (1) and tighten to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Install the engine front cover to water pump bolt (1) and tighten to 25 N.m (18 lb ft).
6. Reposition the oxygen sensor harness to the front cover.
7. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-491134-S07083805762012073000000) .
8. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-491134-S16705107472012073000000) .
9. Install the engine mount bracket (1). Refer to «Engine Mount Bracket Replacement»(ref-491134-S35350701452012073000000) .

Camshaft Timing Chain, Sprocket, and Tensioner Replacement

Special Tools

1. EN-45027 Tensioner Tool
2. EN-45059 Angle Meter
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
2. Remove the number 1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
3. Rotate the crankshaft in the engine rotational direction clockwise, until the number 1 piston is at top dead center (TDC) on the exhaust stroke.
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-491134-S10177369492012073000000)
5. Remove the upper timing chain guide bolts and guide.
6. Remove the timing chain tensioner.
7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
8. Remove and discard the exhaust camshaft actuator bolt (2).
9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
10. Remove the timing chain tensioner guide bolt and guide.
11. Remove the fixed timing chain guide access plug.
12. Remove the fixed timing chain guide bolts and guide.
13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
14. Remove and discard the intake camshaft actuator bolt (2).
15. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head.
16. Remove the outer friction washer (1) if equipped.
17. Ensure the crankshaft gear timing mark (2) is in the 5 o'clock position and crankshaft key is in the 12 o'clock position.
18. Remove the crankshaft sprocket (3).
19. Remove the inner friction washer (1).

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
3. Install the inner friction washer (1).
4. Install the crankshaft sprocket with the timing mark (2) is in the 5 o'clock position and facing outward.
5. Install the outer friction washer (1) if equipped.
6. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
7. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
8. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
9. Hand tighten the new intake camshaft actuator bolt.
10. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (1) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
11. Install the friction washer, if applicable.
12. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
13. Install the adjustable timing chain guide (2) down through the opening in the cylinder head and install the adjustable timing chain bolt (1). Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
14. Install the exhaust camshaft actuator (2) into the timing chain with the timing mark lined up with the second matching colored link.
15. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
16. Use 24 mm open ended wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
17. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
18. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
19. Install the fixed timing chain guide and bolts. Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
20. Install the upper timing chain guide and bolts. Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
21. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Remove the sealing collar from the piston assembly. Install the EN-45027-2 tool (2) into a vise. Install the notch end of the piston assembly into the EN-45027-2 tool (2). Using the EN-45027-1 tool (1), turn the ratchet cylinder into the piston. Reinstall the sealing collar to the piston assembly. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
22. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
23. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
24. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 N.m (55 lb ft).
25. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
26. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 N.m (89 lb in).
27. Using a torque wrench, tighten the camshaft actuator bolt to 30 N.m (22 lb ft) plus 100 degrees using the EN-45059 meter.
28. Remove the EN-48953 locking tool.
29. Install the timing chain oiling nozzle (2). Tighten the timing chain oiling nozzle (1) bolt to 10 N.m (89 lb in).
30. Apply sealant compound to the thread of the timing chain guide bolt access hole plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
31. Install the timing chain guide bolt access hole plug. Tighten the access hole plug to 90 N.m (66 lb ft).
32. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-491134-S10177369492012073000000) .
33. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
34. Install the number 1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .

1. Remove the camshaft timing chain, sprocket, and tensioner. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-491134-S41692950102012073000000) .
2. Remove the adjustable balance shaft chain guide bolt and guide
3. Remove the small balance shaft drive chain guide bolts and guide.
4. Remove the upper balance shaft drive chain guide bolts and guide.
5. Remove the balance shaft drive chain (7).
6. Remove the balance shaft drive sprocket.

1. Install the balance shaft drive sprocket (3).
2. Install the balance shaft drive chain (7) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
3. Install the upper balance shaft drive chain guide and bolts and tighten to 12 N.m (106 lb in).
4. Install the small balance shaft drive chain guide and bolts and tighten to 12 N.m (106 lb in).
5. Install the adjustable balance shaft chain guide and bolt and tighten to 10 N.m (89 lb in).
6. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
7. Install the balance shaft drive chain tensioner and bolts and tighten to 10 N•m (89 lb in).
8. Remove the paper clip from the balance shaft drive chain tensioner.
9. Install the camshaft timing chain, sprocket, and tensioner. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-491134-S41692950102012073000000) .

Scheme 10

Camshaft Cover Replacement

Timing Chain Tensioner Replacement

Special Tools

EN-45027 Tensioner Tool

For equivalent regional tools, refer to Special Tools .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Remove the sealing collar from the piston assembly. Install the EN-45027-2 tool (2) into a vise. Install the notch end of the piston assembly into the EN-45027-2 tool (2). Using the EN-45027-1 tool (1), turn the ratchet cylinder into the piston. Install the sealing collar to the piston. Install the piston assembly to the body of the tensioner. Install the snap ring.
4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .

1. Remove the intake camshaft position actuator. Refer «Camshaft Position Intake Actuator Replacement»(ref-491134-S14905693472012073000000) , «Camshaft Position Intake Actuator Replacement»(ref-491134-S26881439842012073000000) .
2. Remove the intake camshaft position actuator solenoid valve bolt (1) and valve (2).
3. Remove the rear cylinder head cover plate (1).
4. Remove the intake camshaft bearing rear cap bolts and cap (2).
5. Mark camshaft caps to ensure they are installed in the same position.
6. Remove the intake camshaft cap bolts.
7. Remove the camshaft caps (1).
8. Remove the intake camshaft (3).
9. Remove the intake camshaft roller finger followers.
10. Remove the hydraulic lash adjusters.

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
3. Lubricate the valve tips. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
5. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
6. Ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
7. Set the intake camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
8. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.
9. Install the intake camshaft with the notch on the front at approximately the 10 o'clock position (2).
10. Install the camshaft caps and hand start the camshaft cap bolts.
11. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 N.m (89 lb in).
12. Apply a 2.5 mm bead of sealer to the cylinder head at the number 6 intake camshaft rear cap mating surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
13. Install the number 6 intake camshaft rear cap. Tighten the cap bolts evenly to 5 N.m (44 lb in). Tighten the cap bolts evenly to 10 N.m (89 lb in). Back the cap bolts out 120 degrees. Tighten the cap bolts evenly a final pass to 10 N.m (89 lb in).
14. Remove all excess sealing material from the fuel pump roller lifter bore (1), and ensure the bore is free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.
15. Remove all excess sealing material from the fuel pump assembly sealing surface (2).
16. Verify the seal on the cylinder head cover plate (1) is intact and in good condition.
17. Ensure that the opening plate sealing surface is clean and free of excess sealing material. Install the rear cylinder head opening plate (1) and tighten the bolts to 10 N.m (89 lb in).
18. Install the intake camshaft position actuator solenoid valve (2). Tighten the solenoid valve bolt (1) to 10 N.m (89 lb in).
19. Install the intake camshaft position actuator. Refer «Camshaft Position Intake Actuator Replacement»(ref-491134-S14905693472012073000000) , «Camshaft Position Intake Actuator Replacement»(ref-491134-S26881439842012073000000) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-491134-S40350093742012073000000) .
2. Remove the exhaust camshaft position actuator solenoid valve bolt (1) and valve (2).
3. Mark camshaft caps to ensure they are installed in the same position.
4. Remove the exhaust camshaft cap bolts.
5. Remove the camshaft caps ensuring they are marked and refitted in same position on assembly.
6. Remove the exhaust camshaft.
7. Remove the exhaust camshaft roller finger followers.
8. Remove the hydraulic lash adjusters.

1. Install the hydraulic lash adjusters into their bores in the cylinder head and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
2. Lubricate the valve tips. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
3. Position the roller followers on the tip of the valve stem and on the lash adjuster and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
4. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
5. Ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
6. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
7. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.
8. Install the exhaust camshaft with the notch on the front (1) at approximately the 7 o'clock position.
9. Install the camshaft caps and hand start the camshaft cap bolts.
10. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 N.m (89 lb in).
11. Install the exhaust camshaft position actuator solenoid valve (2). Tighten the solenoid valve bolt (1) to 10 N.m (89 lb in).
12. Install the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-491134-S40350093742012073000000) .

Camshaft Position Intake Actuator Replacement

Special Tools

1. EN-45059 Angle Meter
2. EN-48749 Timing Chain Retention Tool Kit
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
3. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
4. Remove the right engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(ref-491148-S12586373482012073000000) .
5. Rotate the crankshaft clockwise and install the EN-48953 retention tool (1).
6. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
7. Use a wrench on the camshaft flats to hold the camshaft.
8. Loosen, but DO NOT remove the intake camshaft actuator bolt.
9. Remove the EN-48953 locking tool (1).
10. Clean the timing chain and gears with solvent.
11. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
12. Remove the upper timing chain guide bolts and guide.
13. Remove the timing chain tensioner.
14. Install the EN-48749 retention tool (1) to the intake side of the timing chain.
15. Install the EN-48749 retention tool (1) to the exhaust side of the timing chain.
16. Remove and discard the intake camshaft actuator bolt (1).
17. Rotate the exhaust camshaft clockwise slightly to take the tension off of the timing chain on the intake actuator.
18. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft rotating the exhaust camshaft clockwise, if required.
3. Install a NEW intake camshaft actuator bolt (1) until snug.
4. Remove the timing chain retention tool (1) from the intake side of the timing chain.
5. Remove the timing chain retention tool (1) from the exhaust side of the timing chain.
6. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(ref-491134-S15008436002012073000000) .
7. Install the EN-48953 retention tool (1).
8. Install the camshaft actuator retention tool bolts and tighten to 10 N.m (89 lb in).
9. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft) plus an additional 100 degrees using the EN-45059 meter. Use a wrench on the camshaft flats to hold the camshaft while tightening the fastener.
10. Remove the EN-48953 retention tool (1).
11. Install the upper timing chain guide and bolts and tighten to 10 N.m (89 lb in).
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
13. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
14. Install the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(ref-491148-S12586373482012073000000) .
15. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .

Special Tools

1. EN-45059 Angle Meter
2. EN-48749 Timing Chain Retention Tool Kit
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
3. Rotate the crankshaft clockwise and install the EN-48953 retention tool (1).
4. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
5. Loosen, but DO NOT remove the intake camshaft actuator bolt.
6. Remove the EN-48953 locking tool (1).
7. Clean the timing chain and gears with solvent.
8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
9. Remove the upper timing chain guide bolts and guide.
10. Remove the timing chain tensioner.
11. Install the EN-48749 retention tool (1) to the intake side of the timing chain.
12. Install the EN-48749 retention tool (1) to the exhaust side of the timing chain.
13. Remove and discard the intake camshaft actuator bolt (1).
14. Rotate the exhaust camshaft clockwise slightly to take the tension off of the timing chain on the intake actuator.
15. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft rotating the exhaust camshaft clockwise, if required.
3. Install a NEW intake camshaft actuator bolt (1) until snug.
4. Remove the timing chain retention tool (1) from the intake side of the timing chain.
5. Remove the timing chain retention tool (1) from the exhaust side of the timing chain.
6. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(ref-491134-S15008436002012073000000) .
7. Install the EN-48953 retention tool (1).
8. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
9. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft) plus an additional 100 degrees using the EN-45059 meter.
10. To release the tensioner apply a counterclockwise rotational torque to the crankshaft balancer bolt of 45 N.m (33 lb ft).
11. Remove the EN-48953 retention tool (1).
12. Install the upper timing chain guide and bolts and tighten to 10 N.m (89 lb in).
13. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
14. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .

Camshaft Position Exhaust Actuator Replacement

Special Tools

1. EN-45059 Angle Meter
2. EN-48749 Timing Chain Retention Tool Kit
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
3. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
4. Remove the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(ref-491148-S12586373482012073000000) .
5. Rotate the crankshaft clockwise and install the EN-48953 locking tool (1).
6. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
7. Use a wrench on the camshaft flats to hold the camshaft.
8. Loosen, but do not remove the exhaust camshaft actuator bolt.
9. Remove the EN-48953 locking tool (1).
10. Clean the timing chain and gears with solvent.
11. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
12. Remove the upper timing chain guide bolts and guide.
13. Remove the timing chain tensioner.
14. Install the EN-48749 retention tool (1) to the exhaust side of the timing chain.
15. Remove and discard the exhaust camshaft actuator bolt (2).
16. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the EN-48749 retention tool (1) from the exhaust side of the timing chain.
5. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(ref-491134-S15008436002012073000000) .
6. Install the EN-48953 locking tool (1).
7. Install the camshaft actuator retention tool bolts and tighten 10 N.m (89 lb in).
8. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft) plus an additional 100 degrees using the EN-45059 meter. Use a wrench on the camshaft flats to hold while tightening the fastener.
9. Remove the camshaft actuator retainer EN-48953 locking tool (1).
10. Install the upper timing chain guide and bolts and tighten to 10 N.m (89 lb in).
11. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
13. Install the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(ref-491148-S12586373482012073000000) .
14. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .

Valve Stem Oil Seal and Valve Spring Replacement

Special Tools

1. EN-36017 Valve Guide Seal Remover
2. EN-43649 Valve Spring Compressor
3. EN-43649-10 Valve Spring Compressor Adaptor Set
4. EN-43653 Flywheel Holding Tool

For equivalent regional tools refer to Special Tools .

Note. Prevent the crankshaft from rotating clockwise or counterclockwise before using compressed air in the cylinder. Rotation of the crankshaft may cause damage to EN-43653 holding tool.

1. If equipped, with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set.
2. If equipped, with an automatic transmission, remove the starter. Refer to «Starter Replacement (LAF or LEA)»(ref-491171-S40433381052012073000000) .
3. If equipped with automatic transmission, install EN-43653 holding tool.
4. Remove the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-491134-S26077527372012073000000) , or «Exhaust Camshaft and Valve Lifter Replacement»(ref-491134-S27825513212012073000000) .
5. Remove the camshaft roller followers (1).
6. Install the EN-43649-10 adaptor set (1) to the front and rear of the cylinder head.
7. Install the cross bars and locks (2) of the EN-43649 compressor to the valve spring compressor adaptors.
8. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
9. Install an air hose adapter into the spark plug hole.
10. Attach an air hose to the adapter and pressurize the cylinder to 690 kPa (100 psi).
11. Compress the valve spring using the valve spring compressor (3).
12. Remove the valve spring keepers (1).
13. Remove the valve spring (3) and retainer (2).
14. Use the EN-36017 seal remover (1) to remove the valve seal.
15. Repeat steps 9-14 for additional cylinders.

1. Using the EN-36017 seal remover (1) install the NEW valve seal. Fully seat the seal onto the valve guide.
2. Install the valve spring (3) and retainer (2).
3. Compress the valve spring using the valve spring compressor.
4. Install the valve spring keepers (1).
5. Disconnect the air hose and air hose adapter.
6. Repeat steps 1-5 for additional cylinders.
7. Remove the EN-43649 compressor and EN-43649-10 adaptor set from the cylinder head.
8. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
9. Install the camshaft roller followers.
10. Install the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-491134-S26077527372012073000000) , or «Exhaust Camshaft and Valve Lifter Replacement»(ref-491134-S27825513212012073000000) .
11. If used, remove the EN-43653 holding tool.
12. If removed, install the starter. Refer to «Starter Replacement (LAF or LEA)»(ref-491171-S40433381052012073000000) .

Cylinder Head Replacement

Special Tools

1. J 45059 Angle Meter
2. EN-48953 Camshaft Actuator Locking Tool
3. J 38185 Hose Clamp Pliers
4. EN-48749 Timing Chain Retention Tool Kit

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-491221-S11227726582012073000000) , «Cooling System Draining and Filling (Static LAF or LEA)»(ref-491221-S24420276232012073000000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LEA)»(ref-491179-S16207312842012073000000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-491134-S07249273782012073000000) .
4. Reposition the radiator surge tank air bleed hose clamp.
5. Remove the radiator surge tank air bleed hose from the cylinder head.
6. Reposition the radiator inlet hose clamp using the J 38185 hose clamp pliers.
7. Remove the radiator inlet hose from the cylinder head.
8. Disconnect all electrical connectors as necessary.
9. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000)
10. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
11. Rotate the crankshaft clockwise to install the EN-48953 camshaft actuator locking tool.
12. Install the EN-48953 camshaft actuator locking tool (1).
13. Install the camshaft actuator tool and tighten bolts to 10 N.m (89 lb in).
14. Remove the upper timing chain guide bolts and guide.
15. Clean the timing chain and gears with solvent.
16. Mark the timing gear sprockets and the timing chain. It is recommended that the paint marks are located in the 12 o'clock position.
17. Loosen, but do not remove the intake and exhaust camshaft actuator bolts.
18. Remove the EN-48953 camshaft actuator locking tool.
19. Install the EN-48749 timing chain retention tool kit (1) to the intake side of the timing chain.
20. Remove the timing chain tensioner.
21. Install the EN-48749 timing chain retention tool kit (1) to the exhaust side of the timing chain.
22. Remove and discard the exhaust camshaft actuator bolt (2).
23. Remove the exhaust cam actuator (3) from the exhaust camshaft while also removing the actuator from the chain.
24. Remove and discard the intake camshaft actuator bolt (2).
25. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.
26. Mark the cylinder head (1) in relationship to the camshaft actuator notch is on the camshaft (2).
27. Mark the cylinder head (1) in relationship to the camshaft actuator notch is on the camshaft (2).
28. Remove the fixed timing chain guide access plug.
29. Remove the upper fixed timing chain guide bolt.
30. Install a rubber band (1) around the top of the upper timing chain guides (2) in order to pull the guides together.
31. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
32. Remove the cylinder head.
33. Remove the cylinder head gasket.
34. Clean all of the gasket surfaces.
35. Use the following steps when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface. NOTE: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block. NOTE: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket. Hold the razor blade as parallel to the gasket surface as possible.
36. Clean the old sealer/lube and any dirt from around the bolt holes.
37. Clean the bolts holes with a nylon bristle brush.
38. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.
39. If replacing the cylinder head, transfer all parts as necessary.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Install NEW cylinder head bolts.
4. Install and tighten the cylinder head bolts in the sequence shown to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059 angle meter.
5. Install the NEW front cylinder head bolts and tighten the bolts to 35 N.m (26 lb ft).
6. Ensure the cylinder head (1) and the camshaft (2) are correctly aligned.
7. Ensure the cylinder head (1) and the camshaft (2) are correctly aligned.
8. Remove the rubber band (1) from around the top of the upper timing chain guides (2).
9. Install the fixed guide bolt into the cylinder head and tighten to 12 N.m (106 lb in).
10. Apply sealant compound to thread and install the timing chain guide bolt access hole plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) for the correct part number.
11. Install the fixed timing chain guide access plug and tighten the plug to 90 N.m (59 lb ft).
12. Install the timing chain onto the intake camshaft actuator.
13. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
14. Install a NEW intake camshaft actuator bolt (2) until snug.
15. Remove the EN-48749 timing chain retention tool (1) from the intake side of the timing chain.
16. Install the timing chain onto the exhaust camshaft actuator.
17. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
18. Install a NEW exhaust camshaft actuator bolt (2) until snug.
19. Remove the EN-48749 timing chain retention tool (1) from the exhaust side of the timing chain.
20. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(ref-491134-S15008436002012073000000) .
21. Install the EN-48953 camshaft actuator locking tool (1) to the actuators.
22. Install the camshaft actuator locking tool bolts and tighten to 10 N.m (89 lb in).
23. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft), plus an additional 100 degrees using the J 45059 angle meter.
24. Release the tensioner by applying a counterclockwise rotational torque of 45 N.m (33 lb ft) to the harmonic balancer bolt.
25. Remove the camshaft actuator locking tool, EN-48953 camshaft actuator locking tool.
26. Install the upper timing chain guide bolts and guide. Tighten the bolts to 10 N.m (89 lb in).
27. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-491134-S34496543642012073000000) .
28. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-491198-S18035247222012073000000) .
29. Connect all electrical connectors as necessary.
30. Install the radiator inlet hose to the cylinder head.
31. Position the radiator inlet hose clamp using the J 38185 hose clamp pliers.
32. Install the radiator surge tank air bleed hose to the cylinder head.
33. Position the radiator surge tank air bleed hose clamp.
34. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LEA)»(ref-491179-S16207312842012073000000) .
35. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-491134-S07249273782012073000000) .
36. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-491221-S11227726582012073000000) , «Cooling System Draining and Filling (Static LAF or LEA)»(ref-491221-S24420276232012073000000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-491134-S36357288892012073000000) .
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement»(ref-491134-S05147048042012073000000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
4. Loosen the upper air conditioning (A/C) compressor bolts.
5. Remove the lower A/C compressor bolt.
6. Remove the lower 2 power brake booster pump bolts (1).
7. Reposition the pump away from the oil pan.
8. Place a suitable drain pan under the oil pan drain plug.
9. Remove the oil pan drain plug.
10. Drain the engine oil.
11. Reinstall the oil pan drain plug until snug.
12. Remove the 4 oil pan to transaxle bolts.
13. Remove the oil pan bolts (1).
14. Remove the oil pan.
15. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
3. Install the oil pan.
4. Install the oil pan bolts.
5. Install the 4 oil pan to transaxle bolts (1) and tighten to 75 N.m (55 lb ft).
6. Tighten the oil pan bolts in the sequence shown to 25 N.m (18 lb ft).
7. Install the power brake booster pump bolts (1).
8. Tighten the power brake booster pump M8 bolt to 22 N.m (16 lb ft).
9. Tighten the power brake booster pump M10 bolt to 50 N.m (37 lb ft).
10. Install the A/C Compressor bolts tighten bolt to 20 N.m (15 lb ft).
11. Lower the vehicle.
12. Install the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement»(ref-491134-S05147048042012073000000) .
13. Install the drive belt. Refer to «Drive Belt Replacement»(ref-491134-S36357288892012073000000) .
14. Fill the engine oil to the proper level.

Scheme 11

Piston Oil Nozzle Replacement

Piston, Connecting Rod, and Bearing Replacement

Special Tools

1. EN-8037 Ring Compressor
2. EN-24270 Cylinder Bore Ridge Reamer
3. EN-43966-1 Connecting Rod Guides
4. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-491134-S36436299682012073000000) .
2. Remove the cylinder head. Refer to «Cylinder Head Replacement»(ref-491134-S08191638272012073000000) .
3. If a ring ridge is present, remove the ring ridge as follows: Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use a EN-24270 reamer to remove the ring ridge. Turn the crankshaft so the piston is at top of the stroke. Remove the cloth and cutting debris.
4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts.
5. Remove the connecting rod and the piston out of the top of the engine block using the EN-43966-1 guides.
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

1. Coat the following parts with engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the piston into its original bore using the EN-43966-1 guides.
3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the EN-8037 compressor firmly against the engine block until all the piston rings have entered the cylinder bore.
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.
8. Install the new connecting rod bolts and nuts. On the first pass, tighten the nuts evenly to 25 N.m (18 lb ft). On the final pass, use the EN-45059 meter in order to tighten the nuts an additional 100 degrees.
9. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-491134-S08191638272012073000000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-491134-S36436299682012073000000) .

Scheme 12

Engine Flywheel Replacement

Crankshaft Rear Oil Seal Replacement

Special Tools

EN-42067 Rear Main Seal Installer

For equivalent regional tools, refer to Special Tools .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-491134-S07635205872012073000000)
2. Use a suitable tool to remove the crankshaft rear oil seal (1).

Scheme 13

1. Using the (2) EN-42067 installer, install a NEW crankshaft real oil seal (1).
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-491134-S07635205872012073000000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-491198-S04073832962012073000000) .
4. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .
5. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-491198-S30425081712012073000000) .
6. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491198-S03222845352012073000000) .
7. Remove the fuel feed pipe clip (2) from the fuel line bracket.
8. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-491134-S07249273782012073000000) .
9. Remove the engine control module cover and disconnect electrical connectors.
10. Remove the accessory wiring junction block, disconnect and reposition wiring harness to engine. Refer to «Accessory Wiring Junction Block Replacement»(ref-491162-S33119106372012073000000) .
11. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LEA)»(ref-491179-S41696619082012073000000) .
12. Remove the oxygen sensors. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(ref-491198-S40133544062012073000000) , and «Heated Oxygen Sensor Replacement - Sensor 2»(ref-491198-S03547161882012073000000) .
13. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
14. Remove the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-491142-S07742607732012073000000) .
15. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-491221-S11227726582012073000000) , «Cooling System Draining and Filling (Static LAF or LEA)»(ref-491221-S24420276232012073000000) .
16. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-491134-S19417908152012073000000) .
17. Lower the vehicle.
18. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
19. Remove the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.
20. Remove the coolant recovery inlet hose clamp (2) at the cylinder head.
21. Remove the coolant recovery inlet pipe from the fuel pump cover.
22. Remove the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.
23. Reposition the radiator inlet hose clamp using the BO-38185 pliers.
24. Remove the radiator inlet hose from the cylinder head.
25. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LEA)»(ref-491221-S20174371622012073000000) .
26. Reposition the heater inlet hose clamp at the thermostat housing.
27. Remove the heater inlet hose from the thermostat housing.
28. Remove the heater outlet hose clamp and hose at thermostat housing.
29. Reposition the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.
30. Remove the coolant recovery reservoir/heater inlet hose (2) from the thermostat housing.
31. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
32. Disconnect the engine wiring harness electrical connector from the air conditioning (A/C) compressor.
33. Unbolt the A/C compressor and reposition and secure out of the way.
34. Remove the negative battery cable lead from the transaxle stud. Reposition the negative battery cable out of the way.
35. Remove the starter. Refer to «Starter Replacement (LAF or LEA)»(ref-491171-S40433381052012073000000) .
36. Lower the vehicle.
37. Remove the transaxle shift cable from the range select lever.
38. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
39. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
40. Raise the vehicle.
41. Remove the left engine splash shield. Refer to «Engine Splash Shield Replacement - Left Side»(ref-491148-S17809704662012073000000) .
42. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the engine cradle.
43. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the engine frame.
44. Drain the transaxle fluid.
45. Remove the transaxle oil cooler line to transaxle nut (1).
46. Remove the transaxle oil cooler lines from the transaxle.
47. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
48. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.
49. Remove and discard both outer tie rod to steering knuckle nuts.
50. Use the CH-24319-B puller.
51. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.
52. Remove and discard both of the lower control arm ball stud cotter pins.
53. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.
54. Use the J-43828 separator.
55. Remove the ball stud nuts.
56. Remove the wheel drive shafts. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
57. Lower the vehicle.
58. Remove the engine mount to engine mount bracket bolts (2).
59. Remove the transaxle mount to transaxle adapter bolts.
60. Disconnect electrical connectors and harnesses as necessary.
61. Raise the vehicle.
62. Position a engine support table under the powertrain assembly.
63. With the table positioned, fully raise the table to contact with the powertrain assembly.
64. Remove the frame to body bolts. Discard the bolts.
65. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle.
66. Remove the torque converter to flexplate bolts (1).
67. Disconnect the electrical harnesses as necessary.
68. Install a suitable lifting devise to the engine.
69. Remove the transaxle bolts from the engine.
70. Separate the engine from the transaxle.
71. Install the engine to a suitable engine stand.

1. Install a suitable lifting devise to the engine.
2. Using the lifting devise, position and install the engine to the transaxle.
3. Install the transaxle bolts to the engine and tighten the bolts to 75 N.m (55 lb ft).
4. Install the torque converter to flexplate bolts (1) and tighten to 62 N.m (46 lb ft).
5. Connect the electrical harnesses as necessary.
6. Remove the engine lifting devise.
7. Position the powertrain and support table under the vehicle.
8. Raise the powertrain into position under the vehicle.
9. With the table positioned, if required, lower the vehicle over the powertrain.
10. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
11. Install the NEW frame to body bolts and tighten to 155 N.m (114 lb ft).
12. Lower the vehicle.
13. Install the transaxle mount to transaxle adapter bolts and tighten to 50 N.m (37 lb ft).
14. Install the engine mount to engine mount bracket bolts (2).
15. Tighten the engine mount to bracket bolts in the following sequence: Middle Rear Front Tighten the bolts to 58 N.m (43 lb ft).
16. Raise and support the vehicle.
17. Install the wheel drive shafts. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
18. Install the control arm ball studs into the steering knuckles.
19. Install the ball stud nuts and tighten to 10 N.m (89 lb in) plus 165 degrees.
20. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.
21. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts. Tighten the nuts to 85 N.m (63 lb ft).
22. Connect the outer tie rods to the steering knuckles.
23. Use the J-44015 installer.
24. Remove the J-44015 installer.
25. Install NEW outer tie rod to steering knuckle nuts and tighten to 25 N.m (18 lb ft) plus 90 degrees.
26. Position the intermediate shaft to the steering gear and install a NEW pinch bolt. Tighten the bolt to 36 N.m (27 lb ft).
27. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
28. Install the transaxle oil cooler lines to the transaxle.
29. Install the transaxle oil cooler line to transaxle nut (1) and tighten to 22 N.m (16 lb ft).
30. Remove the wood from between the oil pan and the engine cradle.
31. Remove the wood from between the transaxle and the engine cradle.
32. Install the engine splash shield. Refer to «Engine Splash Shield Replacement - Left Side»(ref-491148-S17809704662012073000000) .
33. Install the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-491142-S07742607732012073000000) .
34. Lower the vehicle.
35. Un-secure and position the radiator/condenser/fan assembly.
36. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
37. Install the transaxle shift cable to the range select lever.
38. Raise and support the vehicle.
39. Install the oxygen sensors. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(ref-491198-S40133544062012073000000) , and «Heated Oxygen Sensor Replacement - Sensor 2»(ref-491198-S03547161882012073000000) .
40. Instal the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LEA)»(ref-491179-S41696619082012073000000) .
41. Install the engine control module. Refer to «Engine Control Module Replacement»(ref-491198-S31959675392012073000000) .
42. Install the starter. Refer to «Starter Replacement (LAF or LEA)»(ref-491171-S40433381052012073000000) .
43. Position the negative battery cable and install the negative battery cable lead (2) to the transaxle stud.
44. Install the engine wiring harness ground lead nut (1) to the transaxle stud and tighten the nut to 50 N.m (37 lb ft).
45. Position the A/C compressor and install the bolts and tighten to 22 N.m (16 lb ft).
46. Connect the engine wiring harness electrical connector to the A/C compressor.
47. Lower the vehicle.
48. Install the coolant recovery reservoir/heater inlet hose (2) to the thermostat housing.
49. Position the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.
50. Install the heater inlet hose (3) to the thermostat housing.
51. Position the heater inlet hose clamp at the thermostat housing.
52. Connect the radiator inlet hose to the cylinder head.
53. Reposition the radiator inlet hose clamp using the BO-38185 pliers.
54. Connect the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LEA)»(ref-491221-S20174371622012073000000) .
55. Position and install the coolant recovery inlet hose (1) to the cylinder head.
56. Install the coolant recovery inlet pipe to the fuel pump cover.
57. Install the coolant recovery inlet hose clamp (2) at the cylinder head.
58. Position and install the vacuum brake booster hose (2) to the intake manifold.
59. Position the vacuum brake booster hose clamp (1) at the intake manifold.
60. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-491134-S07249273782012073000000) .
61. Install the fuel feed pipe clip (2) to the fuel line bracket.
62. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491198-S03222845352012073000000) .
63. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-491198-S30425081712012073000000) .
64. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-491198-S04073832962012073000000) .
65. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-491198-S04410955102012073000000) .
66. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-491221-S11227726582012073000000) , «Cooling System Draining and Filling (Static LAF or LEA)»(ref-491221-S24420276232012073000000) .
67. Fill the transaxle with fluid. Refer to «Transmission Fluid Drain and Fill»(ref-491164-S06618089182012073000000) .
68. Refill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-491134-S19417908152012073000000) .
69. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-491198-S38852889252012073000000) .
70. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.

Engine Oil and Oil Filter Replacement

Special Tools

EN-44887 Oil Filter Wrench

For equivalent regional tools, refer to Special Tools

1. Place a collecting pan underneath the oil filter.
2. Use EN-44887 wrench to remove the oil filter cap (1) and seal.
3. Remove and properly dispose of the oil filter insert (2).
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
5. Place a collecting pan underneath the oil drain plug.
6. Remove the oil drain plug (1) and seal (2).

1. Clean the oil drain plug thread and the thread in the oil pan.
2. Install a seal (2) to the oil drain plug (1).
3. Install the oil drain plug to the oil pan and tighten to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Use EN-44887 wrench to Install a NEW oil filter (2) and a NEW seal and tighten the oil filter cap (1) to 22 N.m (16 lb ft).
6. Fill in NEW engine oil. Refer to «Engine Mechanical Specifications (LAF, LEA, or LUK)»(ref-491134-S07132447052012073000000) .
7. Reset the service interval indicator.

Draining Fluids and Oil Filter Removal

Special Tools

EN-44887 Oil Filter Wrench

For equivalent regional tools, refer to Special Tools .

1. Use EN-44887 wrench to remove the oil filter cap (1). Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter (2) from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug and tighten to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant to the water pump drain plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
7. Install the water pump drain plug and tighten to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

Special Tools

EN 43653 Flywheel Holding Tool

For equivalent regional tools, refer to Special Tools

1. Install EN 43653 holding tool (1) in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
2. Remove the balancer retaining bolt (1) and washer. Discard the bolt.
3. Remove the balancer (2) using a universal removal tool.

Engine Flywheel Removal

Special Tools

EN 43653 Flywheel Holding Tool

For equivalent regional tools, refer to Special Tools

1. Ensure that EN 43653 tool is installed and engaging the flywheel to prevent crankshaft rotation.
2. Remove the flywheel attaching bolts.
3. Remove the flywheel.
4. Remove EN 43653 tool.

Oil Level Indicator and Tube Removal (LAF, LEA, or LUK)

1. Remove knock sensor connector (4) from the oil level indicator tube.
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket bolt (3).
4. Remove the oil level indicator (2) and the oil level indicator tube (1) from the oil pan.
5. Inspect the O-ring and replace if necessary.

Exhaust Manifold Removal (LAF, LEA, or LUK)

1. Remove the secondary air injection bolts (2) and nuts (1).
2. Remove the secondary air injection studs (3 and 4).
3. Remove the secondary air injection valve assembly (1).
4. Remove the secondary air injection gasket (2) and discard.
5. Remove the oxygen sensor (1).
6. Remove the exhaust manifold heat shield bolts.
7. Remove the exhaust manifold heat shield (1).
8. Remove the block heater (1), if equipped.
9. Remove and discard the exhaust manifold to cylinder head retaining nuts (1).
10. Remove the exhaust manifold (2).
11. Remove the exhaust manifold gasket (3).
12. Clean all of the sealing surfaces.
13. If the exhaust manifold is being replaced, transfer the following parts: The exhaust manifold heat shield The oxygen sensor
14. Remove the secondary air injection pipe assembly bolts (2).
15. Remove the secondary air injection pipe assembly (1).

Intake Manifold Removal

1. Remove the oil fill cap (1).
2. Remove the intake manifold cover (2).
3. Remove the oil fill tube assembly (3) and O-ring (4).
4. Remove the evaporative (EVAP) emission canister valve tube (1).
5. Remove the EVAP canister valve (2).
6. Remove the MAP sensor (3).
7. Remove the throttle body (1).
8. Remove the fuel pump cover nut, bolts, and cover (3).
9. Remove the bracket bolt and low pressure fuel pipe assembly (1).
10. Remove the fuel pump insulator (2).
11. Remove and discard the fuel feed intermediate pipe (1).
12. Remove the fuel pump assembly (4).
13. Remove and discard the fuel pump housing O-ring (2) and gasket (3).
14. Remove the fuel pump roller lifter (1).
15. Remove the fuel rail harness connector bracket bolt (1) and intake manifold insulator bolt.
16. Remove the intake manifold insulator (2).
17. Remove the intake manifold retaining nuts and bolts.
18. Remove the intake manifold (1).
19. If the intake manifold needs to be replaced, transfer the throttle body to the new intake manifold.

Fuel Rail and Injectors Removal

Special Tools

EN-49248 Fuel Rail Assembly Remover

For equivalent regional tools, refer to Special Tools

1. Remove the fuel injection fuel rail noise shield (1).
2. Disconnect the electrical harness from the fuel rail harness connection.
3. Disconnect all 4 fuel injector electrical connections.
4. Remove the fuel rail assembly retaining bolts.
5. Install EN-49248 studs (1) into the 2 center fuel rail assembly retaining bolt locations. Tighten the studs to 22 N.m (16 lb ft).
6. Install EN-49248 remover (2) onto each stud, and engage the hooks to the fuel rail. Install the nuts (3) retaining the remover onto the studs and tighten until snug.
7. Using EN-49248 remover, remove the fuel rail assembly (1).

Camshaft Cover Removal (LAF, LEA, or LUK)

1. Remove the rear lift bracket (1).
2. Remove the front lift bracket (1).
3. Remove the ignition coil (1).
4. Remove the camshaft housing cover insulator (1).
5. Remove the camshaft cover assembly (1).
6. Remove and discard the camshaft cover gasket, camshaft cover grommets, and camshaft cover bolts if they are serviced with the grommet.

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner bolt.
2. Remove the accessory drive belt tensioner (1).
3. Remove the engine front cover bolts (1).
4. Remove the long water pump bolt.
5. Remove the engine front cover (1) and gaskets (2).
6. Remove the crankshaft front cover oil seal with an appropriate tool.

Camshaft Timing Chain and Tensioner Removal (LAF, LEA, or LUK)

Special Tools

EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Rotate the crankshaft to install EN-48953 locking tool (1).
2. Install EN-48953 locking tool onto the cylinder head and tighten to 10 N.m (89 lb in). If the intake camshaft actuator is moving independent of cam and is not locked, rotate the intake camshaft counterclockwise and the tool will hold the actuator, locking the actuator to the cam.
3. Loosen the intake camshaft actuator bolt.
4. Loosen the exhaust camshaft actuator bolt.
5. Remove EN-48953 locking tool.
6. Remove the upper timing chain guide bolts.
7. Remove the upper timing chain guide (1).
8. Remove the timing chain tensioner plunger (1).
9. Locate hex on the exhaust camshaft and hold with a wrench (2).
10. Remove the exhaust camshaft bolt and the exhaust camshaft actuator (1). Discard the bolt.
11. Remove the adjustable timing chain guide bolt.
12. Remove the adjustable timing chain guide (1).
13. Remove the plug (1) to gain access to the fixed timing chain guide bolt.
14. Remove the fixed timing chain guide bolts.
15. Remove the fixed timing chain guide (1).
16. Locate hex on the intake camshaft and hold with a wrench.
17. Remove the intake camshaft actuator bolt, the intake camshaft actuator (1) and the timing chain (2) through the top of the cylinder head. Discard the bolt.
18. Mark the cylinder head where the exhaust camshaft actuator locking notch (1) and intake camshaft locking notch (2) are lined up with the cylinder head.
19. Remove the crankshaft sprocket (2) and friction washers (1), if equipped.
20. Remove the timing chain oil nozzle bolt.
21. Remove the timing chain oil nozzle (1).

Intake Camshaft and Components Removal

1. Remove the intake camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Remove the rear cylinder head cover plate (1).
3. Remove the intake camshaft bearing rear cap bolts and cap (2).
4. Mark camshaft caps to ensure they are installed in the same position.
5. Remove the intake camshaft cap bolts.
6. Remove the camshaft caps (1).
7. Remove the intake camshaft (3).
8. Remove the intake camshaft roller finger followers.
9. Remove the hydraulic lash adjusters.

Exhaust Camshaft and Components Removal

1. Remove the exhaust camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Mark camshaft caps to ensure they are installed in the same position.
3. Remove the exhaust camshaft cap bolts.
4. Remove the camshaft caps ensuring they are marked and refitted in same position on assembly.
5. Remove the exhaust camshaft.
6. Remove the exhaust camshaft roller finger followers.
7. Remove the hydraulic lash adjusters.

Water Pump and Balance Shaft Chain and Tensioner Removal

1. Remove the balance shaft drive chain tensioner bolts.
2. Remove the balance shaft drive chain tensioner (1).
3. Remove the adjustable balance shaft chain guide bolt.
4. Remove the adjustable balance shaft chain guide (1).
5. Remove the small balance shaft drive chain guide bolts.
6. Remove the small balance shaft drive chain guide (1).
7. Remove the upper balance shaft drive chain guide bolts.
8. Remove the upper balance shaft drive chain guide (1).
9. Remove the balance shaft drive chain (1).
10. Remove the balance shaft drive sprocket (2).

Balance Shaft Removal

Note. This procedure is not used in Europe.

Special Tools

EN-43650 Balancer Shaft Bearing Remover and Installer

For equivalent regional tools, refer to Special Tools .

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies (1).
3. Install the EN-43650 remover (1) into the balance shaft hole. Insert the tool with the foot parallel to the shaft.
4. When the EN-43650 remover (1) is inserted in the block turn the EN-43650 remover so that the foot becomes perpendicular to the shaft.
5. Center the foot of the EN-43650 remover on the balance shaft bushing.
6. Once the EN-43650 remover is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench (2). When the EN-43650 remover is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in) (a) from the block face. If the EN-43650 remover is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
7. Tighten the nut on the EN-43650 remover (1) until the tension releases. When the tension releases, remove the EN-43650 remover and the balance shaft bushing (2).

Water Pump Removal

1. Remove the engine coolant temperature sensor (1).
2. Remove the thermostat and water feed pipe retaining bolts.
3. Remove the thermostat housing and water feed pipe (1) from the water pump cover.
4. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
5. Remove the water pump assembly (1).

Cylinder Head Removal (LAF, LEA, or LUK)

Special Tools

EN 38188 Cylinder Head Broken Bolt Extractor Kit

For equivalent regional tools, refer to Special Tools

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Clean all of the gasket surfaces.
5. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. NOTE: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. NOTE: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
6. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the bolt holes with a nylon bristle brush.
8. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the EN 38188 kit.

Oil Pan Removal

1. Remove the oil pan bolts.
2. Remove the oil pan at pry points.

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap (1).
6. Install EN-43966-1 guides (2) on the connecting rod bolts before removing the piston and connecting rod assembly.
7. Remove the piston and connecting rod assembly (1).

Lower Crankcase Removal

1. Remove the bedplate perimeter bolts (3).
2. Remove and discard the crankshaft bearing bolts (2).
3. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase (1).

Crankshaft and Bearing Removal

1. Remove the crankshaft (1) from the block.
2. Remove the crankshaft rear oil seal (2) from the block.
3. Remove the bearing inserts (1) from the block (2).
4. Remove the bearing inserts (1) from the bed plate (2).
5. Clean the oil, sludge, and carbon.
6. Inspect the oil passages for obstructions.
7. Inspect the threads.
8. Inspect the bearing journals and the thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating (discoloration)
9. Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists find the cause and repair it.
10. Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selection of bearing inserts. If not within limits the crankshaft must be replaced. Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

Crankshaft and Bearing Installation

Special Tools

1. EN-8087 Cylinder Bore Checking Gauge
2. EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

Scheme 14

Note. Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for use. If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure

1. Tighten the bedplate to specification using the EN 45059 meter.
2. Measure the bearing bore for taper and out-of-round using the EN-8087 gauge (1).
3. No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2 methods to measure bearing clearance. Method A gives more reliable results and is preferred. Method A yields measurement from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
2. To measure bearing clearance using Method A, use the following procedure: Measure the crankshaft bearing journal diameter with a micrometer (1) in several places, 90 degrees apart. Average the measurements. Measure the crankshaft bearing journal taper and runout. Install the lower crankcase and tighten the bearing cap bolts to specification. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing ID measurement to determine clearance. Determine whether clearance is within specification. If out of specification, choose different inserts. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer.
3. To measure bearing clearance using Method B, use the following procedure: Clean the used bearing inserts. Install the used bearing inserts. Place a piece of gaging plastic across the entire bearing width. Install the bearing caps. CAUTION: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Install the bearing cap bolts to specification. NOTE: Do not rotate the crankshaft. Remove the bearing cap, leaving the gauging plastic in place. It does not matter whether the gauging plastic adheres to the journal or to the bearing cap. Measure the gauging plastic at its widest point with the scale (1) printed on the gauging plastic package. Remove the gauging plastic.

Lower Crankcase Installation

Special Tools

EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the upper crankshaft bearings (1) and lubricate bearing surfaces with engine oil.
2. Install the crankshaft (1) on the journals.
3. Install the lower bearing halves (1), without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply a 4.25 mm bead of sealer, dimension (a), directly in the groove of the block to bedplate mating surfaces. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
5. Install the lower crankcase (1). Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the EN 45059 meter an additional 70 degrees.
7. Tighten the lower crankcase perimeter bolts in sequence to 25 N.m (18 lb ft).

Piston, Connecting Rod, and Bearing Installation (LAF, LAT, LE5, LE9, LEA, or LUK)

Note. This procedure is not used in Europe.

Special Tools

1. EN-43966 Connecting Rod Guides
2. EN 45059 Angle Meter
3. EN-47836 Piston Ring Compressor

For equivalent regional tools, refer to Special Tools .

1. Install the connecting rod bearings. Use NEW bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the EN-43966 guides (1) into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install EN-47836 compressor, piston, and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-47836 compressor against the engine block until all the rings have entered the cylinder bore. Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap (1).
5. Install the connecting rod bolts. Always use new bolts. Tighten the connecting rod bolts to 25 N.m (18 lb ft), plus 100 degrees using the EN 45059 meter.
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gauge (1). The correct clearance is 0.07-0.37 mm (0.0027-0.0145 in).

Cylinder Head Installation (LAF, LEA, or LUK)

Special Tools

EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools

1. Install the cylinder head gasket to the block.
2. Install the cylinder head. Ensure the number 1 cylinder is at top dead center (TDC). The key on the crankshaft should be on top in the 12 o'clock position.
3. Install the cylinder head bolts. Tighten the bolts in sequence to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence using the EN 45059 meter.
4. Install the front cylinder head bolts and tighten to 30 N.m (22 lb ft).

Exhaust Camshaft Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
2. Lubricate the valve tips. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
3. Position the roller followers on the tip of the valve stem and on the lash adjuster and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
4. When installing the camshafts, ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
5. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
6. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.
7. Install the exhaust camshaft with the notch on the front (1) at approximately the 7 o'clock position.
8. Install the camshaft caps and hand start the camshaft cap bolts.
9. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 N.m (89 lb in).
10. Install the exhaust camshaft position actuator solenoid valve (2). Tighten the solenoid valve bolt (1) to 10 N.m (89 lb in).

Intake Camshaft Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
3. Lubricate the valve tips. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
5. When installing the camshafts, ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
6. Set the intake camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
7. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.
8. Install the intake camshaft with the notch on the front at approximately the 10 o'clock position (2).
9. Install the camshaft caps and hand start the camshaft cap bolts.
10. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 N.m (89 lb in).
11. Apply a 2.5 mm bead of sealer to the cylinder head at the number 6 intake camshaft rear cap mating surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
12. Install the number 6 intake camshaft rear cap. Tighten the cap bolts evenly to 5 N.m (44 lb in). Tighten the cap bolts evenly to 10 N.m (89 lb in). Back the cap bolts out 120 degrees. Tighten the cap bolts evenly a final pass to 10 N.m (89 lb in).
13. Remove all excess sealing material from the fuel pump roller lifter bore (1), and ensure the bore is free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.
14. Remove all excess sealing material from the fuel pump assembly sealing surface (2).
15. Verify the seal on the cylinder head cover plate (1) is intact and in good condition.
16. Ensure that the opening plate sealing surface is clean and free of excess sealing material. Install the rear cylinder head opening plate (1) and tighten the bolts to 10 N.m (89 lb in).
17. Install the intake camshaft position actuator solenoid valve (2). Tighten the solenoid valve bolt (1) to 10 N.m (89 lb in).

Balance Shaft Installation

Note. This procedure is not used in Europe.

Special Tools

EN-43650 Balance Shaft Bushing Remover/Installer

For equivalent regional tools, refer to Special Tools .

1. Install the balance shaft bushing using the EN-43650 installer (1).
2. Seat the balance shaft bushing into the bore using the EN-43650 installer (1) and a wrench.
3. When the EN-43650 installer is fully seated in the engine block, remove it with a wrench.
4. Place the number one piston at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts (1) into their bores.
7. Install the balance shaft retaining bolts and tighten to 10 N.m (89 lb in).

Water Pump Installation

Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1. Install the water pump assembly (1).
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts to 25 N.m (18 lb ft).
4. Apply sealant to the water pump drain plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
5. Install the water pump drain plug, if necessary. Tighten to 20 N.m (15 lb ft).
6. Install the water feed tube (1).
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing (2) to block bolts and stud and tighten to 10 N.m (89 lb in).
10. Install the engine coolant temperature sensor (1) by hand.
11. Tighten the engine coolant temperature sensor and tighten to 20 N.m (15 lb ft).

Water Pump and Balance Shaft Chain and Tensioner Installation

1. Install the upper balance shaft chain guide (1) and bolts and tighten to 12 N.m (106 lb in).
2. Install the small balance shaft chain guide (1).
3. Install the balance shaft chain guide bolts and tighten to 12 N.m (106 lb in).
4. Install the adjustable balance shaft drive chain guide (1).
5. Install the adjustable balance shaft drive chain guide bolts and tighten to 10 N.m (89 lb in).
6. Reset the timing chain tensioner (1) by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts and tighten to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Camshaft Timing Chain, Sprocket, and Tensioner Installation (LAF, LEA, or LUK)

Special Tools

1. EN-45027 Tensioner Tool
2. EN 45059 Angle Meter
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools .

1. Ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install a friction washer (1), if equipped.
3. Install the timing chain drive sprocket (3) to the crankshaft with the timing mark (2) in the 5 o'clock position and the front of the sprocket facing out.
4. Install a second friction washer (1), if equipped.
5. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
6. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
7. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
8. Hand tighten the new intake camshaft actuator bolt.
9. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (1) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
10. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
11. Install the adjustable timing chain guide (1) down through the opening in the cylinder head and install the adjustable timing chain bolt and tighten to 10 N.m (89 lb in).
12. Install the exhaust camshaft actuator (1) into the timing chain with the timing mark lined up with the second matching colored link.
13. Install the exhaust camshaft actuator (1) onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
14. Using a 23-24 mm open end wrench, rotate the exhaust camshaft clockwise until the dowel pin in the camshaft actuator goes into the camshaft slot.
15. When the actuator (1) seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
16. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
17. Install the fixed timing chain guide (1) and bolts and tighten to 12 N.m (106 lb in).
18. Install the upper timing chain guide (1) and bolts and tighten to 10 N.m (89 lb in).
19. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the EN-45027-2 (2) tensioner into a vise. Install the notch end of the piston assembly into the EN-45027-2 (2) tensioner. Using the EN-45027-1 (1) tensioner, turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
20. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
21. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
22. Install the timing chain tensioner assembly (1) and tighten to 75 N.m (55 lb ft).
23. The crankshaft balancer must be installed in order to release the tensioner. Refer to «Crankshaft Balancer Installation»(ref-491134-S12576592342012073000000) .
24. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 N.m (89 lb in).
25. Using a torque wrench, tighten the intake camshaft actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the EN 45059 meter.
26. Using a torque wrench, tighten the exhaust camshaft actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the EN 45059 meter.
27. Remove EN-48953 locking tool.
28. Install the timing chain oiling nozzle (1) and tighten the bolt to 10 N.m (89 lb in).
29. Apply sealant to the thread of the timing chain guide bolt access hole plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
30. Install the timing chain guide bolt access hole plug (1) and tighten to 75 N.m (55 lb ft).

Engine Front Cover and Oil Pump Installation

1. Install the engine front cover (1) with a new gasket (2).
2. Install the engine front cover bolts and tighten to 25 N.m (18 lb ft).
3. Install the long water pump bolt (1) and tighten to 25 N.m (18 lb ft).
4. Install the accessory drive belt tensioner (1).
5. Install the accessory drive belt tensioner bolt and tighten to 45 N.m (33 lb ft).

Oil Pan Installation

1. Apply a 2.25 mm bead of sealer (1) on the level part of the flange next to the chamfer around the perimeter of the oil pan and the oil suction port opening. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
2. Install the oil pan (1).
3. Install the oil pan bolts and tighten to 25 N.m (18 lb ft) in sequence.

Crankshaft Balancer Installation

Special Tools

1. EN-48585 Crankshaft Balancer Guide
2. EN-48953 Camshaft Actuator Locking Tool
3. EN 38122-A Crankshaft Balancer Holder
4. EN 43653 Flywheel Holding Tool
5. EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the EN 38122-A holder into the end of the crankshaft.
2. Install the balancer (1) onto the EN-48585 guide. Use care to properly align the keyway and flats on the balancer with the oil pump drive.
3. Install the EN 38122-A holder (1).
4. Install a new retaining bolt and washer. Use the EN 38122-A holder and a breaker bar to prevent the crankshaft from rotating when tightening the bolt. Tighten the bolt to 150 N.m (111 lb ft) plus 100 degrees using the EN 45059 meter.
5. Install the EN-48953 locking tool (1) and tighten the bolts into the cylinder head. Tighten the EN-48953 locking tool retaining bolts to 10 N.m (89 lb in).
6. Release the timing chain tensioner by applying 45 N.m (33 lb ft) counterclockwise torque to the crankshaft balancer bolt.
7. Remove the EN-48953 locking tool.

Camshaft Cover Installation (LAF, LEA, or LUK)

1. Install NEW camshaft cover grommets and camshaft cover bolts if they are serviced with the grommet.
2. Assemble the camshaft cover (1) and a NEW gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
3. Install the cover on the cylinder head and hand start the bolts. Tighten the bolts to 10 N.m (89 lb in).
4. Install the camshaft housing cover insulator (1). Tighten the bolts to 10 N.m (89 lb in).
5. Install the ignition coil (1). Tighten the bolt to 10 N.m (89 lb in).
6. Install the front lift bracket (1).
7. Install the front lift bracket bolts and tighten to 25 N.m (18 lb ft).
8. Install the rear lift bracket (1).
9. Install the rear lift bracket bolts and tighten to 25 N.m (18 lb ft).

Oil Filter with Cap and Seal Installation

Special Tools

EN-44887 Oil Filter Wrench

For equivalent regional tools, refer to Special Tools .

1. Install a new oil filter (2) on the oil filter cap (1).
2. Lubricate the O-ring on the oil filter cap with 5W30 engine oil.
3. Use EN-44887 wrench to install the oil filter cap. Tighten the oil filter cap to 25 N.m (18 lb ft).

Fuel Rail and Injectors Installation

Special Tools

EN-47909 Injector Bore and Sleeve Cleaning Kit

For equivalent regional tools, refer to Special Tools .

1. Clean the fuel injector bore in the cylinder head using the EN-47909 kit.
2. Install the fuel rail (1) with injectors into the cylinder head evenly.
3. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.
4. Start and hand tighten the remaining fuel rail bolts. Tighten the bolts in sequence to final torque using the following procedure: Tighten first pass in sequence to 25 N.m (18 lb ft). Tighten final pass in sequence to 25 N.m (18 lb ft).
5. Connect the electrical harness to the fuel rail harness connections.
6. Install the fuel injection fuel rail noise shield (1).

Intake Manifold Installation

Special Tools

EN-48896 HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools .

1. Install the intake manifold studs in the manifold face and tighten to 15 N.m (11 lb ft).
2. Install the intake manifold (1). Start and hand tighten the intake manifold bolts and nuts.
3. Tighten the bolts and nuts in sequence to 25 N.m (18 lb ft).
4. Install the intake manifold insulator (2).
5. Install the insulator bolt and tighten to 10 N.m (89 lb in).
6. Install the fuel rail harness connector bracket (1) to the intake manifold. Tighten the bracket bolt to 10 N.m (89 lb in).
7. Use the EN-48896 alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
8. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.
9. Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.
10. Install a NEW fuel pump housing O-ring (2) and gasket (3).
11. Install the fuel pump assembly (4).
12. Start and hand-tighten the fuel pump assembly bolts evenly. Tighten the fuel pump bolts evenly to 15 N.m (11 lb ft).
13. Install and hand-tighten both ends of the NEW high pressure fuel line (1). Tighten the high pressure fuel line fitting nuts to 30 N.m (22 lb ft).
14. Install the fuel pump insulator (2).
15. Install the low pressure fuel pipe assembly (1).
16. Install the fuel pump cover (3) and nut. Tighten the nut to 10 N.m (89 lb in).
17. Install the fuel pump cover bolts. Tighten the bolts to 10 N.m (89 lb in).
18. Install a new throttle body gasket.
19. Install the throttle body (1).
20. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
21. Install the MAP sensor (3). Tighten the sensor bolt to 4 N.m (35 lb in).
22. Install the EVAP canister valve (2) and tighten to 25 N.m (18 lb ft).
23. Install the EVAP canister valve tube (1).
24. Install the O-ring and oil fill tube assembly (3).
25. Install the intake manifold cover (2) onto the camshaft cover ball studs.
26. Install the oil fill cap (1).

Exhaust Manifold Installation (LAF, LEA, or LUK)

1. Install new exhaust manifold studs and tighten to 10 N.m (89 lb in).
2. Install the secondary air injection pipe assembly (1).
3. Install the secondary air injection pipe assembly bolts (2) and tighten to 10 N.m (89 lb in).
4. Install the exhaust manifold gasket (3).
5. Install the exhaust manifold (2) to the cylinder head.
6. Install NEW exhaust manifold to cylinder head retaining nuts (1) finger tight.
7. Tighten the NEW exhaust manifold to cylinder head retaining nuts two passes in sequence: Tighten first pass in sequence to 14 N.m (124 lb in). Tighten final pass in sequence to 14 N.m (124 lb in).
8. Install the block heater (1). Tighten the bolt to 10 N.m (89 lb in).
9. Install the exhaust manifold heat shield (1).
10. Install the exhaust manifold heat shield bolts and tighten to 9 N.m (80 lb in).
11. Coat the threads of the oxygen sensor (1) with antiseize. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
12. Install the oxygen sensor and tighten to 42 N.m (31 lb ft).
13. Install the secondary air injection studs (3 and 4) and tighten to 10 N.m (89 lb in).
14. Install the secondary air injection valve assembly (1) with a NEW gasket (2).
15. Install the secondary air injection bolts (2 and 3) and nuts (1). Tighten the secondary air injection assembly to cylinder head bolts (3) to 22 N.m (16 lb ft). Tighten the secondary air injection assembly to pipe assembly bolts (2) to 10 N.m (89 lb in). Tighten the secondary air injection assembly nuts (1) to 22 N.m (16 lb ft).

Oil Level Indicator and Tube Installation (LAF, LEA, or LUK)

1. Lubricate the oil level indicator tube O-ring. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491134-S31490395222012073000000) .
2. Install the oil level indicator (2) and the oil level indicator tube (1) into the oil pan.
3. Install the oil level indicator tube bracket bolt (3) to the intake manifold and tighten to 10 N.m (89 lb in).
4. Install the electrical wiring harness to the oil level indicator tube.
5. Install the knock sensor wiring clip (4) into the oil level indicator tube.

Engine Flywheel Installation

Special Tools

1. EN-38122-A Crankshaft Balancer Holder
2. EN-43653 Flywheel Holding Tool
3. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the flywheel.
2. Install NEW bolts.
3. Holding the crankshaft balancer with EN-38122-A holder, tighten the bolts evenly. Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the EN-45059 meter