Basic Engine, 2.0L: Removal & Installation Saab 9-5 II

Installation Procedure

1. Remove the EN-49212-1 camshaft fixer and EN-49212-2 camshaft fixer .
2. Install the camshaft cover. Refer to «Camshaft Cover Removal (LDK, LHU)»(ref-653636-S02456269882014090100000) .

Removal Procedure

1. Remove the timing chain tensioner. Refer to «Timing Chain and Tensioner (LDK, LHU) Removal»(ref-653636-S09079441362014090100000) .
2. Remove the oil pump gear. Refer to «OIL PUMP GEAR REPLACEMENT»(ref-653636-S19646961252014090100000) .
3. Remove the timing chain guide - adjustable. Refer to «TIMING CHAIN GUIDE REPLACEMENT»(ref-653636-S39609514802014090100000) .
4. Remove the timing chain guide - fixed. Refer to «TIMING CHAIN GUIDE REPLACEMENT»(ref-653636-S39609514802014090100000) .
5. Remove the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
6. Remove the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
7. Remove the camshaft position actuator replacement - intake. Refer to «CAMSHAFT POSITION INTAKE ACTUATOR REPLACEMENT»(ref-653636-S17786895342014090100000) .
8. Remove the timing chain oil nozzle. Refer to «TIMING CHAIN OIL NOZZLE REPLACEMENT»(ref-653636-S38909950932014090100000) .
9. Remove the camshaft timing chain.

Scheme 29

Scheme 30

Scheme 31

1. Install the camshaft position actuator - intake (1) but do not tighten yet. Refer to «CAMSHAFT POSITION INTAKE ACTUATOR REPLACEMENT»(ref-653636-S17786895342014090100000) .
2. Install the timing chain (2). Lay the timing chain (2) about the intake camshaft wheel (1). Fix the intake camshaft with the EN-49212-2 camshaft fixer (3).
3. Install the timing chain guide - fixed. Refer to «TIMING CHAIN GUIDE REPLACEMENT»(ref-653636-S39609514802014090100000) .
4. Install the timing chain guide - adjustable. Refer to «TIMING CHAIN GUIDE REPLACEMENT»(ref-653636-S39609514802014090100000) .
5. Install the timing chain oil nozzle. Refer to «TIMING CHAIN OIL NOZZLE REPLACEMENT»(ref-653636-S38909950932014090100000) .
6. Install the oil pump gear. Refer to «OIL PUMP GEAR REPLACEMENT»(ref-653636-S19646961252014090100000) . Turn the crankshaft (1) on the set marks (2).
7. Install the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) . Count the number of the end to end connectors of the camshaft timing chain between the mark on the intake camshaft drive pulley and the mark on the exhaust camshaft drive pulley. The timing chain must have 29 end to end connectors to guarantee a correct adjustment. During assembly it is necessary to tension the timing chain. Turn the camshaft in clockwise direction to install the exhaust camshaft drive pulley. Install the exhaust camshaft drive pulley and fixes with that fastener in the camshaft.
8. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Tighten the camshaft position actuator - exhaust to 30 Nm (22 lb ft) 100 degrees . Hold up the exhaust camshaft with a wrench.
9. Tighten the camshaft position actuator - intake to 30 Nm (22 lb ft) 100 degrees Hold up the intake camshaft with a wrench.
10. Fix the exhaust camshaft with the EN-49212-1 camshaft fixer. Check everything over again. Remove the EN-49212 camshaft fixer.
11. Install the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
12. Install the timing chain tensioner. Refer to «Timing Chain and Tensioner (LDK, LHU) Removal»(ref-653636-S09079441362014090100000) .
13. Turn the crankshaft two round and examine the track tension and the attitudes again.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Remove the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
2. Remove the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
3. Remove the camshaft position actuator - intake. Refer to «CAMSHAFT POSITION INTAKE ACTUATOR REPLACEMENT»(ref-653636-S17786895342014090100000) .
4. Remove the cylinder head opening plate. Refer to «CYLINDER HEAD OPENING PLATE REPLACEMENT»(ref-653636-S07485350142014090100000) .
5. Remove the fuel pump module. Refer to «FUEL PUMP MODULE REPLACEMENT»(ref-653646-S36448140112014090100000) .
6. Remove the 12 fasteners (1) from the camshaft bearing caps (2).
7. Remove with caution the camshaft bearing caps (2) from the cylinder head.
8. Remove the intake camshaft (1).
9. Remove the valve lifters (2).

Scheme 40

Scheme 41

1. Install the valve lifters (1). Employ the valve lifters with a little bit oil
2. Install the intake camshaft (2). Employ the camshaft with a little bit oil
3. Install the intake camshaft bearing caps (1) and camshaft bearing cap fasteners (2). Tighten the fasteners to 10 Nm (89 lb in) .
4. Install the cylinder head opening plate. Refer to «CYLINDER HEAD OPENING PLATE REPLACEMENT»(ref-653636-S07485350142014090100000) .
5. Install the fuel pump module. Refer to «FUEL PUMP MODULE REPLACEMENT»(ref-653646-S36448140112014090100000) .
6. Install the camshaft position actuator - intake. Refer to «CAMSHAFT POSITION INTAKE ACTUATOR REPLACEMENT»(ref-653636-S17786895342014090100000) .
7. Install the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
8. Install the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .

Scheme 42

Scheme 43

1. Remove the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
2. Release the camshaft timing chain. Refer to «Timing Chain Replacement»(ref-653636-S19414239132014090100000) .
3. Remove the power brake booster pump. Refer to «POWER BRAKE BOOSTER PUMP REPLACEMENT (LHU/A20NFT)»(ref-653650-S11721733212014090100000) .
4. Remove the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
5. Remove the 12 fasteners (1) from the camshaft bearing caps (2).
6. Remove with caution the camshaft bearing cap (2) from the cylinder head.
7. Remove the exhaust camshaft (1).
8. Remove the valve lifter (2).

Scheme 44

Scheme 45

1. Install the valve lifter (1). Employ the valve lifter with engine oil
2. Install the exhaust camshaft (2). Employ the camshaft with engine oil
3. Install the camshaft bearing caps (1) and camshaft bearing cap fasteners (2). Tighten the fasteners to 10 Nm (89 lb in) .
4. Install the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
5. Install the camshaft timing chain. Refer to «Timing Chain Replacement»(ref-653636-S19414239132014090100000) .
6. Install the power brake booster pump. Refer to «POWER BRAKE BOOSTER PUMP REPLACEMENT (LHU/A20NFT)»(ref-653650-S11721733212014090100000) .
7. Install the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .

Scheme 46

Scheme 47

Note. Clean working is condition.

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

1. Remove the spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-653646-S38475264822014090100000) .
2. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
3. Remove both camshaft position actuator solenoid valves. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
4. Remove the intake and the exhaust camshaft. Refer to «INTAKE CAMSHAFT AND VALVE LIFTER REPLACEMENT»(ref-653636-S35708854832014090100000) and «EXHAUST CAMSHAFT AND VALVE LIFTER REPLACEMENT»(ref-653636-S26758958632014090100000) .
5. Tighten one of the support head (1) in the center of the rail (2) with the fastener (3).
6. Install the EN-6086-5 mounting shaft (1) to one of the EN-6086-6 supports (2).
7. Install the EN-6086-8 knuckle (1) to the EN-6086-5 mounting shaft (2) and install the second support (3) to the mounting shaft (2).
8. Install the lever arm bracket (1) to the cylinder head (2). The fixed side of the lever arm bracket install on the left side of the cylinder head but do not tighten yet. The not fixed side of the lever arm bracket install on the right side of the cylinder head but do not tighten yet.
9. Fix the EN-6086-5 mounting shaft (1) with both support head fasteners (2).
10. Align the lever arm bracket (1) in the center of the cylinder head on the basis of the spark plug drillings (2).
11. Tighten both EN-6086-6 supports to the cylinder head.
12. Fix the second support head (1) to the rail (2). Release the heated oxygen sensor 1 electrical connector from the cylinder head.
13. NOTE: All wheels must be in contact with the ground. Fix the crankshaft. Use a suitable tool.
14. Install the EN-6086-15 compressed air adapter (1) to the spark plug drill (2) of the first cylinder.
15. Subject the first cylinder with compression air.
16. Install the EN-6086-12 adapter part small (1) to the EN-6086-11 removal part small (2).
17. Install the EN-6086-12 adapter part small and the EN-6086-11 removal part small to position 3 to the EN-6086-7 lever arm. Fasten the tools with EN-6086-2 pin.
18. Install the EN-6086-7 lever arm to the EN-6086-8 knuckle. Use the position 1 of the lever arm. Fasten the tools with EN-6086-2 pin.
19. NOTE: Note the installation construction units position of the valve stem keys, valve spring retainer and valve spring. Set the EN-6086-11 removal part small (1) on the intake valve spring retainer (2) on the left side of the first cylinder.
20. To remove the valve stem key (1), valve spring retainer (2) and valve spring (3) press the lever arm downward.
21. NOTE: Do not use magnetic tools. If the valve stem key are out fallen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper.
22. Set the EN-6086-11 removal part small on that intake valve spring retainer on the right side to the first cylinder.
23. To remove from the valve stem keys, valve spring retainer and valve spring press the lever arm downward.
24. NOTE: Do not use magnetic tools. If the valve stem key has become loose, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper.
25. Remove both valve stem oil seal rings with EN-840 valve stem oil seal remover (1) from the cylinder head.
26. Install the small part of the EN-6086-12 adapter and EN-6086-11 , the small part to be removed in position 1 on the EN-6086-7 lever. Fasten the tools using the EN-6086-2 pin.
27. Install the EN-6086-7 lever arm to the EN-6086-8 knuckle. Use the position 3 to the lever arm. Fasten the tools with EN-6086-2 pin.
28. NOTE: Note the position of the valve stem keys, valve spring retainer and valve spring. Set the EN-6086-11 removal part small on that exhaust valve spring retainer on the left side at the first cylinder.
29. To remove the valve stem key, valve spring retainer and valve spring press the lever arm upward.
30. NOTE: Do not use magnetic tools. If the valve stem key are loosen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper.
31. Set the EN-6086-11 removal part small on that exhaust valve spring retainer on the right side to the first cylinder.
32. To remove the valve stem keys, valve spring retainer and valve spring press the lever arm upward.
33. NOTE: Do not use magnetic tools. If the valve stem key are loosen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper.
34. Remove the both valve stem oil seal rings with EN-840 valve stem oil seal remover from the cylinder head.

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. NOTE: Do not press the valve downward. Install with EN-6152 valve stem oil seal installer (1) the new valve stem oil seal rings to the cylinder head. Press the valve stem oil seal ring with the finger downward. The EN-6152 valve stem oil seal installer must rest upon at the lower edge of the valve stem oil seal ring. Knock with a rubber hammer on the EN-6152 valve stem oil seal installer to sit the valve stem oil seal ring to the cylinder head.
2. Install EN-6086-100-15 pressure adapter 6 (3) to the EN-6086-100-10 mounting part (4). Remove the fastener (1) from the mounting part (4). Remove the spring (2) from the mounting part (4). Install the pressure adapter 6 (3) into the mounting part (4). Install the spring (2) into the mounting part (4). Install the fastener (1) to the mounting part (4).
3. NOTE: Only one attempt. If the attempt failed, repeat step 3 to 8 for the exhaust left side and step 9 to 13 for the exhaust right side. Install the valve stem keys (1) to the EN-6086-100-10 mounting part (2). Pull the ring back that the springs are loosen. Install the valve stem keys with the narrow side upward. Pull the ring forward till the springs are the valve stem keys locking.
4. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part.
5. Install both parts to the EN-6086-7 lever arm.
6. Install the left exhaust valve spring and the left exhaust valve retainer to the cylinder head.
7. Set the EN-6086-100-15 pressure adapter to the left exhaust valve.
8. Press the lever arm up to audibly engage the left valve stem keys.
9. Install the valve stem keys to the EN-6086-100-10 mounting part. Pull the ring back that the springs are loosen. Install the valve stem keys with the narrow side upward. Pull the ring forward till the springs are the valve stem keys locking.
10. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part.
11. Install both parts to the EN-6086-7 lever arm.
12. Install the right exhaust valve spring and the right exhaust valve retainer to the cylinder head.
13. Set the EN-6086-100-15 pressure adapter to the right exhaust valve.
14. Press the lever arm up to audibly engage the right valve stem keys.
15. Remove the EN-6086-7 lever arm from the EN-6086-8 knuckle.
16. Install the EN-6086-7 lever arm (1) to the EN-6086-8 knuckle (2). Use the position 1 from the lever arm. Fasten the tools with EN-6086-2 pin.
17. NOTE: Do not press the valve downward. Install with EN-6152 valve stem oil seal installer (1) the new valve stem oil seal rings to the cylinder head. Press the valve stem oil seal ring with the finger downward. The EN-6152 valve stem oil seal installer must rest upon at the lower edge of the valve stem oil seal ring. Knock with a rubber hammer on the EN-6152 valve stem oil seal installer to sit the valve stem oil seal ring to the cylinder head.
18. NOTE: Only one attempt. If the attempt failed, repeat step 18 to 23 for the intake left side and step 24 to 29 for the intake right side. Install the valve stem keys to the EN-6086-100-10 mounting part. Pull the ring back that the springs are loosen. Install the valve stem keys with the narrow side upward. Pull the ring forward till the springs are the valve stem keys locking.
19. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part.
20. Install both parts to the EN-6086-7 lever arm.
21. Install the left intake valve spring and the left intake valve retainer to the cylinder head.
22. Set the EN-6086-100-15 pressure adapter to the left intake valve.
23. Press the lever arm down to audibly engage the left valve stem keys.
24. Install the valve stem keys (1) to the EN-6086-100-10 mounting part (2). Pull the ring back that the springs are loosen. Install the valve stem keys with the narrow side upward. Pull the ring forward till the springs are the valve stem keys locking.
25. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part.
26. Install both parts to the EN-6086-7 lever arm.
27. Install the right intake valve spring and the right intake valve retainer to the cylinder head.
28. Set the EN-6086-100-15 pressure adapter to the right intake valve.
29. Press the lever arm down to audibly engage the right valve stem keys.
30. Remove the EN-6086-7 lever arm from the EN-6086-8 knuckle.
31. To replace the valve stem oil seals of the cylinders 2 and 3 turn the crankshaft by 180 degrees . Set 2 marks (1), by 180 degrees transferred, at the oil pump housing. Set 1 mark (2) at the crankshaft balancer. A second mechanic must hold the primary timing chain upward. Turn clock wise the timing chain 180 degrees .
32. To remove the valve stem oil seals repeat the steps from removal 15 to 35.
33. To install the valve stem oil seals repeat the steps from installation 1 to 31.
34. Turn back the crankshaft 180 degrees against clockwise direction after the exchange of the valve stem sealings of the cylinder 2 and 3. A second mechanic must hold the primary timing chain upward.
35. Remove the lever arm bracket.
36. Install the intake and exhaust camshaft and valve lifter. Refer to «INTAKE CAMSHAFT AND VALVE LIFTER REPLACEMENT»(ref-653636-S35708854832014090100000) and «EXHAUST CAMSHAFT AND VALVE LIFTER REPLACEMENT»(ref-653636-S26758958632014090100000) .
37. Check the timing chain setting again. Refer to «CAMSHAFT TIMING CHAIN ADJUSTMENT»(ref-653636-S22464627492014090100000) .
38. Install the both camshaft position actuator solenoid valves. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
39. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
40. Install all spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-653646-S38475264822014090100000) .

Scheme 67

Draining Fluids and Oil Filter Removal

Special Tools

EN-44887 Oil Filter Spanner

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 68

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. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the oil sump drain plug and tighten to 25 Nm (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 (LDK, LHU)»(ref-653636-S40994991802014090100000) .
7. Install the water pump drain plug and tighten to 20 Nm (15 lb ft) .
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balance Weight Removal

Special Tools

1. EN-38122-A Crankshaft Balancer Holder
2. EN-43653 Flywheel Holding Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 69

Scheme 70

1. NOTE: EN-43653 flywheel holding tool may be used instead of EN-38122-A crankshaft balancer holder to prevent crankshaft rotation. Install EN-38122-A holder (1).
2. Remove the balancer retaining bolt and washer. Use EN-38122-A holder and a breaker bar to prevent the crankshaft from rotating when loosening the bolt. Discard the bolt.
3. Remove the crankshaft balancer assembly (1) using a universal removal tool.

Engine Flywheel (Automatic Transmission) Removal

Special Tools

EN-43653 Flywheel Holding Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 71

Scheme 72

1. Install EN-43653 flywheel holding tool (1) in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
2. Remove the flywheel attaching bolts.
3. Remove the flywheel (1).
4. Remove EN-43653 flywheel holding tool.

Scheme 73

1. Disconnect the knock sensor from the oil level indicator tube (1).
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator (2) and the oil level indicator tube from the oil pan.
5. Inspect the O-rings for damage. Replace as necessary.

Scheme 74

1. Remove the starter bolts.
2. Remove the starter (1).

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

1. WARNING: Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold can be damaged if it is removed when the engine is hot. NOTE: The charger AIR bypass tube assembly connected from the charger AIR bypass valve solenoid to the charger AIR bypass valve tank assembly is permanently attached to the tank assembly. Do not attempt to disconnect the charger AIR bypass tube assembly at the charger AIR bypass valve tank assembly. Disconnect the charger AIR bypass tube assembly from the intake manifold.
2. Disconnect the charger AIR bypass tube with the retaining clip from the charger AIR bypass valve solenoid.
3. Remove the charger AIR bypass valve tank assembly nut (2).
4. NOTE: The charger AIR bypass bolt is captured on the bracket and should not be removed from the bracket. Loosen the bolt only until it is no longer attached to the block when removing the charger AIR bypass valve tank assembly. Loosen the charger AIR bypass valve tank assembly bolt.
5. Remove the charger AIR bypass valve tank assembly (1).
6. Disconnect the remaining charger AIR bypass tubes at the turbocharger and vehicle.
7. Remove the charger AIR bypass valve solenoid bolts.
8. Remove the charger AIR bypass valve solenoid (1).
9. Remove the high pressure fuel pump cover bolts.
10. Remove the high pressure fuel pump cover (2).
11. Remove the high pressure fuel pump noise insulator (1).
12. WARNING: Fuel coming from the tank under high pressure can cause serious injuries to the skin and eyes. ALWAYS relieve the pressure in the fuel system before removing components under high fuel pressure. Loosen and disconnect the fuel feed line tube nut (1).
13. Remove the fuel feed line bolts.
14. Remove the fuel feed line (2).
15. Inspect the fuel feed line nut for damaged threads.
16. Inspect the fuel feed line sealing bail for damage or debris.
17. Replace the fuel feed line if any damage is found.
18. Remove the throttle body bolts (2).
19. Remove the throttle body (1).
20. Disconnect the rear knock sensor from the intake manifold brace.
21. Remove the intake manifold brace bolt (1) and nut (3).
22. Remove the intake manifold brace (2).
23. Remove the MAP sensor bolt (1) and MAP sensor (2).
24. Remove the EVAP purge solenoid valve bolt (3) and valve (4).
25. Remove the intake manifold bolts and nuts (3).
26. Remove the intake manifold (2).
27. Remove the intake manifold gasket (1).

Fuel Rail and Injector (LDK, LHU) Removal

Special Tools

1. DT-2619-01 Slide Hammer
2. EN-37281-A Injector Remover

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Disconnect the electrical harness from the fuel rail harness connection.
2. Remove the fuel injector noise insulator (1).
3. WARNING: Fuel coming from the tank under high pressure can cause serious injuries to the skin and eyes. ALWAYS relieve the pressure in the fuel system before removing components under high fuel pressure. Remove and discard the high pressure fuel line (1).
4. Disconnect all 4 fuel injector electrical connections.
5. Remove the fuel rail bolts.
6. Remove the fuel rail and fuel injectors (1).
7. NOTE: A fuel injector may remain stuck in the cylinder head. If this occurs, complete the following steps: Remove the fuel injector hold-down clamp before removing the fuel injector.
8. NOTE: Use the injector puller and a slide hammer to pull out the injector straight out axially. The injector must never be bent or twisted during this procedure. Use EN-37281-A remover (2) and DT-2619-01 slide hammer to remove the fuel injector (1).
9. Remove the high pressure fuel pump bolts.
10. Remove the high pressure fuel pump (3).
11. Remove and discard the high pressure fuel pump gasket (1).
12. Remove and discard the high pressure fuel pump O-ring (2).
13. Remove the high pressure fuel pump roller lifter (1).

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

1. Remove the turbocharger heat shield bolts.
2. Remove the turbocharger heat shield (1).
3. Remove the catalytic converter nuts and L-bracket bolts.
4. Remove the catalytic converter (1).
5. Remove the catalytic converter seal (2).
6. Remove the catalytic converter L-bracket nuts and L-bracket (2) from the catalytic converter (1).
7. WARNING: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation. Remove the turbocharger oil feed pipe bolts.
8. Remove the turbocharger oil feed pipe gaskets.
9. Remove the turbocharger oil feed pipe (1).
10. Remove the turbocharger coolant return pipe bolts.
11. Remove the turbocharger coolant return pipe gaskets.
12. Remove the turbocharger coolant return pipe (1).
13. Remove the turbocharger air cooler outlet pipe bolts.
14. Remove the turbocharger air cooler outlet pipe (1).
15. Remove the turbocharger coolant feed pipe bolts.
16. Remove the turbocharger coolant feed pipe gaskets.
17. Remove the turbocharger coolant feed pipe (1).
18. Remove the catalytic converter bracket bolts.
19. Remove the catalytic converter brace (1).
20. Remove the turbocharger brace nuts.
21. Remove the turbocharger brace (1).
22. NOTE: The PCV hose should not be disconnected from the camshaft cover. The PCV hose and the camshaft cover cannot be serviced individually. Remove the PCV hose fitting bolt at the turbocharger.
23. Remove the PCV hose fitting from the turbocharger.
24. Remove the turbocharger nuts (1).
25. Remove the turbocharger (2) and the oil return pipe.
26. Remove the turbocharger gasket (3).
27. Remove the turbocharger oil return pipe bolts (3).
28. Remove the turbocharger oil return pipe (2) from the turbocharger.
29. Remove and discard the turbocharger oil return pipe gasket (1).

Scheme 100

Scheme 101

1. Remove the exhaust manifold heat shield bolts.
2. Remove the exhaust manifold heat shield (1).
3. NOTE: Use an inverted Torx® socket E16 to remove the Torx® nut 3. Remove the exhaust manifold nuts.
4. Remove the exhaust manifold (1).
5. Remove the exhaust manifold gasket (2).

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

1. Remove the rear lift bracket bolts and rear lift bracket (1).
2. Remove the front lift bracket bolts and front lift bracket (1).
3. Remove the power brake booster pump bolts.
4. Remove the power brake booster pump (2).
5. Remove and discard the power brake booster O-ring seal (1).
6. Remove the bolt and coil (1).
7. Remove the camshaft housing cover insulator bolts.
8. Remove the camshaft housing cover insulator (1).
9. NOTE: The PCV hose should not be disconnected from the camshaft cover. The PCV hose and the camshaft cover cannot be serviced individually. Remove the camshaft cover (1).
10. Remove and discard the camshaft cover gasket, camshaft cover grommets, and camshaft cover bolts if they are serviced with the grommets.

Scheme 108

Scheme 109

Scheme 110

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.

Timing Chain and Tensioner (LDK, LHU) Removal

Special Tools

EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU)

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide (1).
3. NOTE: The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If it is not, the timing chain will become cocked and it will be difficult to remove. Remove the timing chain tensioner (1).
4. Rotate intake camshaft actuators to install EN-48953 locking tool (1).
5. NOTE: Marking the chain and actuators is crucial to procedures operation. The camshaft actuator and timing chain must have oil removed from the surface prior to marking both actuators and chain. Install EN-48953 locking tool onto the cylinder head and tighten to 10N m (89 lb in) . If the intake camshaft actuator is moving independent of cam and is not locked, rotate the intake camshaft counter-clockwise and the tool will hold the actuator, locking the actuator to the cam.
6. Loosen the intake camshaft actuator bolt.
7. Loosen the exhaust camshaft actuator bolt.
8. Remove EN-48953 locking tool.
9. Locate hex on the exhaust camshaft and hold with a wrench (2).
10. Remove the exhaust cam bolt and the exhaust cam 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 cam sprocket bolt, the intake cam sprocket (1) and the timing chain (2) through the top of the cylinder head. Discard the bolt.
18. NOTE: The number 3 exhaust valves are open. NOTE: Note the position and direction of the camshafts before removal. Mark the cylinder head in relation to the locking notches before component removal. 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 friction washers (1), if equipped.
20. Remove the crankshaft sprocket (2).
21. Remove the timing chain oil nozzle bolt.
22. Remove the timing chain oil nozzle (1).

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. Remove the intake camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Remove the rear cylinder head opening plate bolts (2) and plate (1).
3. Remove the intake camshaft bearing rear cap bolts and camshaft bearing rear cap (2).
4. NOTE: Remove each bolt on each cap one turn at a time until there is no spring tension pushing on the camshaft. 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. NOTE: Keep all of the roller finger followers and hydraulic lash adjusters in order so that they can be reinstalled in their respective locations. Remove the intake camshaft roller finger followers (1).
9. Remove the hydraulic lash adjusters (1).

Scheme 127

Scheme 128

Scheme 129

Scheme 130

1. Remove the exhaust camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Remove the exhaust camshaft bearing rear cap bolts and exhaust camshaft bearing rear cap (2).
3. NOTE: Remove each bolt on each cap one turn at a time until there is no spring tension pushing on the camshaft. Mark camshaft caps to ensure they are installed in the same position.
4. Remove the exhaust camshaft cap bolts.
5. Remove the camshaft caps (1) ensuring they are marked and refitted in same position on assembly.
6. Remove the exhaust camshaft (3).
7. NOTE: Keep all of the roller finger followers and hydraulic lash adjusters in order so that they can be reinstalled in their respective locations. Remove the exhaust camshaft roller finger followers (1).
8. Remove the hydraulic lash adjusters (1).

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

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. NOTE: It may ease removal of the balance shaft drive chain to get all of the slack in the chain between the crankshaft and water pump sprockets. Remove the balance shaft drive chain (1).
10. Remove the balance shaft drive sprocket (2).

Balancer Shaft Removal

Special Tools

EN-43650 Balancer Shaft Bearing Remover and Installer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 136

Scheme 137

Scheme 138

Scheme 139

1. Remove the balance shaft bearing carrier bolts.
2. NOTE: It is possible to install the intake side balance shaft into the exhaust side and vice versa. Please use care not to install the balance shafts into the wrong bores. Engine vibration will result. Do not remove the bolt holding the sprocket. Remove the balance shaft assemblies (1).
3. WARNING: Proper centering of the tool is required on the balance shaft bushing. If the tool is not properly centered then damage to the bearing bore and block will occur. Install the EN-43650 remover/installer (1) into the balance shaft hole. Insert the tool with the foot parallel to the shaft.
4. When the EN-43650 remover/installer is inserted in the block turn the EN-43650 remover/installer so that the foot becomes perpendicular to the shaft.
5. Center the foot of the EN-43650 remover/installer on the balance shaft bushing.
6. Once the EN-43650 remover/installer 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. When the EN-43650 remover/installer 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/installer is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
7. Tighten the nut on the EN-43650 remover/installer (1) until the tension releases. When the tension releases, remove the EN-43650 remover/installer and the balance shaft bushing (2).

Scheme 140

Scheme 141

Scheme 142

1. Remove the engine coolant temperature sensor (1).
2. Remove the thermostat and water feed pipe retaining bolts.
3. NOTE: Twist the water feed pipe while pulling to remove it from the water pump cover. Remove the thermostat housing (1) and water feed pipe (2) 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 (1).
6. Remove and discard the gasket (2).

Cylinder Head (LDK, LHU) Removal

Special Tools

EN-38188 Cylinder Head Broken Bolt Extractor Kit

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 143

Scheme 144

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. WARNING: In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks. Remove the cylinder head (1).
3. Remove the cylinder head gasket (2).
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 surfaces. 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. NOTE: Do not use a tap to clean the cylinder head bolt holes. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the fastener holes with a nylon bristle brush.
8. WARNING: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals. When cleaning the cylinder head bolt holes, use a suitable solvent in spray form. Use a compressed-air cleaning pistol with an extra long nozzle to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the EN-38188 extractor kit.

Scheme 145

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

Piston, Connecting Rod and Bearing (LDK, LHU) Removal

Special Tools

EN-43966-1 Connecting Rod Guides

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 146

Scheme 147

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 (1) on the connecting rod bolts before removing the piston and connecting rod assembly.
7. Remove the piston and connecting rod assembly (2).

Scheme 148

1. Remove the bedplate perimeter bolts (3).
2. NOTE: Do not forget the 2 outside rear bolts (4). 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).

Scheme 149

Scheme 150

Scheme 151

1. Remove the crankshaft (1) from the block.
2. Remove the crankshaft rear oil seal (2).
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. NOTE: Replace the crankshaft if cracks, severe gouges or burned spots are found. Slight roughness may be removed with a fine polishing cloth soaked in clean engine oil. Burrs may be removed with a fine oil stone. 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.

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plugs (3).
4. Remove the 3 oil passage plugs on each side of the block (2).
5. Remove the 2 water passage plugs on the top of the block (1).
6. Remove the 2 front oil passage plugs.
7. Remove the knock sensors (1).
8. Remove the oil pressure switch (2).
9. Remove the crankshaft position (CKP) sensor (1) and bolt.
10. Inspect the crankshaft position sensor for damage and replace, if necessary.
11. Loosen the piston oil nozzle assembly captured bolts and remove the piston oil nozzle assemblies (1).

Cylinder Liner Removal

Special Tools

EN-45680-850 Cylinder Sleeve Removal and Installation Kit

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 156

Scheme 157

Scheme 158

Scheme 159

1. WARNING: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. WARNING: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install EN-45680-852 cylinder bore sleeve puller (1) through the cylinder bore.
3. WARNING: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller will occur. Align the shoe (1) of EN-45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of EN-45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install EN-456850-851 fixture (4) onto the threaded shaft of EN-456850-852 cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Use four old cylinder head bolts for the attaching bolts. Install the 4 bolts (2) into the cylinder head bolt holes in the block and tighten to 15 Nm (11 lb ft) .
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve (1).
10. WARNING: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. Remove EN-45680-851 fixture, EN-45680-852 cylinder bore sleeve puller and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to «PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION (LDK, LHU)»(ref-653637-S25155690292014090100000) .

Cylinder Liner Installation

Special Tools

EN-45680-850 Cylinder Sleeve Removal and Installation Kit

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

1. WARNING: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. WARNING: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture EN-45680-851 fixture and the EN-45680-853 cylinder bore sleeve installer (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. NOTE: Use four old cylinder head bolts for the attaching bolts. Insert the 4 attachment bolts into the legs of the fixture EN-45680-851 (1).
4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Do not apply downward pressure to the cylinder bore sleeve (117). Tighten the 4 attachment bolts to 15 Nm (11 lb ft) .
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) of the EN-45680-853 cylinder bore sleeve installer onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) of the EN-45680-851 cylinder bore sleeve installer into the groove of fixture (1).
8. WARNING: Do not use any air powered or electric tools to rotate the threaded shaft of the cylinder bore sleeve installer in the fixture assembly or damage to the cylinder bore sleeve will occur. Using a ratchet, rotate the threaded shaft of the EN-45680-853 (1) cylinder bore sleeve installer in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
10. Using a torque wrench, torque the threaded shaft of EN-45680-851 fixture assembly (1) to 102 Nm (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the EN-45680-851 fixture assembly with the EN-45680-853 (1) cylinder bore sleeve installer from the cylinder block (100).

Scheme 168

The EN-45680-861 trim tool assembly (2) contains or requires the following components to complete 2.0L, 86 mm cylinder sleeve trimming

Scheme 169

1. Debris collector (3) with EN-45680-865 filter.
2. Air control valve (1)
3. Drill motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction
4. EN-45680-869 bore cutter bit and screw.
5. EN-45680-899 Bore trimmer pilot, white in color
6. EN-45680-862 Gauge ring assembly. Trim tool preloader (1) Set gauge ring (2)
7. EN-45680-412 Set Gauge Ring (2)
8. EN-45680-863 metal shavings catch plug (3)
9. EN-45680-866 drive adapter (4)
10. EN-45680-864 bolts (5)

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

1. WARNING: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. WARNING: Ensure that all the metal particles are collected in order to prevent internal damage to the engine or bearings. Place EN-45680-863 metal shaving catch plug (1) into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place an additional EN-45680-863 metal shaving catch plug into all remaining cylinder bore sleeves.
4. WARNING: Installing the metal shaving catch plug deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure. WARNING: Installing the metal shaving catch plug above the recommended depth will cause damage to the metal shaving catch plug. Ensure that the EN-45680-863 metal shaving catch plug (1) is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. Ensure that the correct bore trimmer pilot and cutter bit are installed on the EN-45680-861 trimmer base assembly: EN-45680-869 cutter bit and screw EN-45680-899 trimmer pilot, 86 mm sleeve
6. NOTE: Before using the trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. The groove side of the set gauge ring (1) on the EN-45680-862 gage ring assembly should be positioned upward on a flat surface.
7. NOTE: Ensure that the set gauge ring surfaces are clean. Carefully position the EN-45680-861 trim tool assembly onto the set gauge ring.
8. Loosen the shaft collar screw (2).
9. Push the shaft collar (2) downward using the trim tool preloader (1) on the EN-45680-862 gage ring assembly until the shaft collar is positioned against the top of the flange bearing (3).
10. NOTE: Once this procedure is done, it is not necessary to reset the trim tool assembly height until the blades are worn, damaged, or replaced. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 Nm (14 lb ft) .
11. Place the EN-45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
12. Install the EN-45680-864 (2) four bolts into the cylinder head bolt holes and tighten to 20 Nm (15 lb ft) .
13. WARNING: For proper tool operation, a drill motor with a 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur. Fasten the drive adapter EN-45680-866 (1) into the drill chuck.
14. WARNING: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage. Connect a compressed air supply 517.10-861.84 kPa (75-125 psi) to the male quick connect (3) located on EN-45680-861 trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
15. NOTE: It should not take longer than 15 seconds to complete the trimming procedure. If it does, the trimming bits must be repositioned to a new cutting surface. Place the EN-45680-866 drive adapter and drill assembly (1) vertically onto the drive adapter end of EN-45680-861 trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, apply firm downward force until the cutting action is complete.
16. Remove the EN-45680-866 drive adapter (1) and drill assembly from the EN-45680-861 trim tool assembly.
17. Turn off the compressed air valve (2).
18. Remove the EN-45680-861 trim tool assembly from the engine block.
19. Remove any material shavings that may be found on the EN-45680-863 metal shaving catch plug.
20. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the EN-45680-863 metal shaving catch plug.
21. Install a straight edge (2) on the cylinder block perpendicular to the crankshaft center line.
22. Using a light (1), illuminate the backside of the straight edge.
23. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve (2), the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
24. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve (2) is cut correctly.
25. Proceed to the next bore sleeve to be trimmed repeating steps 10 - 23 if necessary.

Scheme 179

1. Clean the crankshaft balancer (1).
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Refer to «SAFETY GLASSES WARNING»(ref-653635-S22428822072014090100000) . Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following conditions: Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust, or other damage must be replaced. Axial cracks in and around the keyway NOTE: In order for the belt to track properly, the belt grooves should be free of all dirt or debris. Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. Minor imperfections may be removed with a fine file. Worn, chunking, or deteriorated rubber between the hub and pulley

Scheme 180

Scheme 181

Scheme 182

1. NOTE: In order to maintain the proper component balance, contact surface taper, and heat transfer, manual transmission flywheels (1) are NOT to be machined. Clean the flywheel in solvent (1, 2).
2. Refer to «SAFETY GLASSES WARNING»(ref-653635-S22428822072014090100000) . Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel (1) for the following conditions: Damaged ring gear teeth Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel. A scored, grooved or damaged friction surface
4. Inspect the automatic transmission flywheel (1) for the following conditions: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations Weight saving holes

Piston and Connecting Rod (LDK, LHU) Removal

Special Tools

1. EN-46745 Piston Clip Retainer Remover/Installer
2. EN-46745-4 Piston Clip Retainer Remover/Installer Adapter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 183

Scheme 184

Scheme 185

1. WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. Disassemble the piston rings (1). Use a suitable tool to expand the rings. The piston rings must not be reused.
2. NOTE: 2 piston pin retainers hold the piston pins in place. No special tools are required to remove the piston pins. Ensure that the piston pin is not damaged. Do not reuse the retainers. Remove the piston pin retainers using the EN-46745 remover (1) and the EN-46745-4 adapter.
3. Remove the piston pin (1) and connecting rod (3) from the piston (2).

Scheme 186

1. Clean the connecting rods (1) in solvent and dry with compressed air.
2. Inspect the connecting rods for the following conditions: Signs of being twisted, bent, nicked, or cracked Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with fine emery cloth. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure: 5.1. Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. 5.2. Using an inside micrometer, measure the connecting rod piston pin bore. 5.3. Subtract the piston pin diameter from the piston pin bore diameter. 5.4. The clearance should not be more than 0.021 mm (0.0008 in).
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.

Scheme 187

Scheme 188

Scheme 189

Scheme 190

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Ensure the oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston (1) Scuffed or damaged skirts (2) Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure: 5.1. Piston pin bores and pins must be free of varnish or scuffing. 5.2. Use an outside micrometer to measure the piston pin in the piston contact areas. 5.3. Using an inside micrometer, measure the piston pin bore. 5.4. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). 5.5. If the clearance is excessive, determine which component is out of specification.
6. Measure the piston ring end gap using the following procedure: 6.1. Place the piston ring in the area of the bore where the piston ring will travel, approximately 25 mm or 1 inch down from the deck surface. Ensure the ring is square with the cylinder bore by positioning the ring with the piston head. 6.2. The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in). The top compression ring end gap should be 0.20-0.35 mm (0.0078-0.0138 in). The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). 6.3. The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in). 6.4. The top compression ring end gap should be 0.20-0.35 mm (0.0078-0.0138 in). 6.5. Measure the end gap of the piston ring with feeler gauges (1). Compare the measurements with those provided below: 6.6. If the clearance exceeds the provided specifications, the piston rings must be replaced. 6.7. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure: 7.1. Roll the piston ring (2) entirely around the piston ring groove. If any binding is caused by a distorted piston ring, replace the ring. 7.2. With the piston ring on the piston, use feeler gauges (1) to measure clearance at multiple locations. 7.3. The clearance between the surface of the top piston ring and the ring land should be no greater than 0.055 mm (0.0022 in). 7.4. If the clearance is greater than specifications, replace the piston ring. 7.5. If the new ring does not reduce the top ring side clearance to 0.055 mm (0.0022 in) or less, install a new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the second compression ring near the end for identification of the top side. Install the second compression ring with the dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than 0.032 mm (0.0012 in).
10. If the new ring does not reduce the clearance to 0.032 mm (0.0012 in) or less, install a new piston.
11. Measure piston width using the following procedure: 11.1. Using an outside micrometer (2), measure the width of the piston (1) 12.5 mm (0.4925 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. 11.2. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. 11.3. The proper clearance specification for the piston is 0.010-0.041 mm (0.0006-0.0016 in).
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replace the piston.

Scheme 191

Scheme 192

Scheme 193

1. NOTE: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores must not have excessive wear or taper. A used piston and pin set may be reinstalled if, after cleaning and inspection, they are within specifications. Inspect the engine block cylinder bore. Refer to «ENGINE BLOCK CLEANING AND INSPECTION»(ref-653636-S06137258852014090100000) .
2. Inspect the piston and the piston pin. Refer to «PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION (LDK, LHU)»(ref-653637-S25155690292014090100000) .
3. Using a bore gauge (1), measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge (1) with a micrometer and record the reading.
5. With a micrometer (2) or caliper at a right angle to the piston, measure the piston (1) 14 mm (0.570 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance. Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) .
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «SEPARATING PARTS»(ref-653636-S34345841302014090100000) .

Piston and Connecting Rod Installation (LDK, LHU)

Special Tools

1. EN-46745 Piston Pin Clip Remover/Installer
2. EN-46745-4 Piston Pin Clip Remover/Installer Adapter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 194

Scheme 195

Scheme 196

1. NOTE: Install the piston onto the connecting rod with the arrow oriented toward the front of the engine. Assemble the connecting rod (2) and the piston (1).
2. WARNING: Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage. Use the following procedure to assemble the piston pin and the retainer: 2.1. Coat the piston pin with oil. 2.2. Using the EN-46745 installer (1) and the EN-46745-4 adapter, install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove. 2.3. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. 2.4. Using the EN-46745 installer and the EN-46745-4 adapter, install the second piston pin retainer. 2.5. Ensure that the piston moves freely.
3. WARNING: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. Install the following components of the oil control ring assembly - bottom ring (6): 3.1. The expander (5) 3.2. The lower oil control ring (4) 3.3. The upper control ring (3)
4. Install the lower compression ring - second ring (2). Place the manufacturer's mark facing up.
5. Install the upper compression ring - top ring (1).

Scheme 197

1. Inspect the camshaft journals and lobes for wear or scoring.
2. Inspect the camshaft sprocket alignment notch for damage.
3. Inspect the exhaust camshaft insert (2) for damage.
4. Inspect the camshaft cover for damage or loose oil control baffles.
5. NOTE: The PCV hose should not be disconnected from the camshaft cover. The PCV hose and the camshaft cover cannot be serviced individually. Inspect the PCV hose (1) attached to the camshaft cover. Replace the camshaft cover if damage to the PCV hose is present.
6. Clean the camshaft cover.
7. Wash the camshaft in solvent.
8. Oil the camshaft.
9. Inspect the camshaft cover for cracks or other signs of damage.

Scheme 198

1. Inspect the timing chain guides (1, 4, 6) for cracking or wear.
2. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the timing chain tensioner shoe for wear.
4. Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
5. Inspect the timing chain (2) and actuators (3, 8) for wear.
6. Inspect the camshaft actuator faces for signs of movement.
7. Inspect the camshaft actuator teeth and chain for signs of excessive wear, chipping, or seizure of the timing chain links.
8. Inspect the oil nozzle body (5) for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body if it is damaged.
9. Inspect the timing chain tensioner (7) for the scoring or free movement.
10. Inspect the timing chain seal for damage. If damaged, replace the seal.

Scheme 199

1. Clean the balance shafts (2) in solvent.
2. Inspect the bearing (1) surfaces on the balance shafts for scoring or unusual wear.
3. Inspect the balance shaft drive sprockets for wear, damage, or missing teeth.
4. Measure the rear bearing journals on the balance shafts, the journals should be 36.723-36.743 mm (1.4458-1.4466 in) in diameter.
5. Measure the front bearing journals on the balance shafts, the front bearing journals should be 20.020-20.000 mm (0.7881-0.7874 in) in diameter.
6. When the balance shafts have been installed in the engine block, check for smooth rotation, sticking, binding, or roughness.

Scheme 200

1. Inspect the balance shaft drive chain guides (3, 5, 8) for cracking or wear.
2. Replace the balance shaft drive chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the balance shaft drive chain tensioner guide shoe for wear. Replace the balance shaft drive chain tensioner guide shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
4. Inspect the balance shaft drive chain (7) and sprockets (2, 4) for wear.
5. NOTE: The crankshaft sprocket is not serviceable. Inspect the crankshaft sprocket (6) faces for signs of movement.
6. Inspect the alignment notch in the balance shaft for cracking or damage.
7. Inspect the water pump (1), crankshaft, and balance shaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the balance shaft drive chain links.
8. Inspect the timing chain tensioner (9) for damage or wear.

Lower Crankcase Installation (LDK, LHU)

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

1. Install the upper crankshaft bearings (1) in the engine block (2) 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 (2). Apply oil to bearing surfaces.
4. NOTE: The block assembly surface must be free of contamination prior to applying the sealer. Install and align the bedplate to block within 20 minutes of applying the sealer. The bedplate must be fastened to final torque specification within 60 minutes of applying the sealer. 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 (LDK, LHU)»(ref-653636-S40994991802014090100000) .
5. Install the lower crankcase (1). Tap gently into place with a suitable tool, if necessary. Ensure the lower crankcase is aligned properly on the dowels.
6. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the NEW crankshaft bearing bolts in sequence finger tight.
7. Tighten the crankshaft bearing bolts: 7.1. Tighten the crankshaft bearing bolts a first pass in sequence to 20 Nm (15 lb ft) . 7.2. Using the EN-45059 angle meter, tighten the crankshaft bearing bolts a final pass in sequence to 70 degrees .
8. NOTE: Do not forget the 2 rear outer bolts. Install the lower crankcase perimeter bolts (1-10) and tighten to 25 Nm (18 lb ft) .

Crankshaft Rear Oil Seal Installation

Special Tools

EN-42067 Rear Main Seal Installer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 208

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the EN-42067 installer (1), press the new crankshaft seal into the housing. The EN-42067 installer also establishes the depth of the seal in the crankshaft seal bore. The seal should be flush to 0.5 mm (0.0197 in) deep.

Piston, Connecting Rod and Bearing Installation (LDK, LHU)

Special Tools

1. EN-43953 Piston Ring Compressor
2. EN-43966-1 Connecting Rod Guides
3. EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 209

Scheme 210

Scheme 211

1. Install the NEW connecting rod bearings. 1.1. Install the bearing inserts into the connecting rod and the connecting rod cap. 1.2. Lubricate the connecting rod bearings with engine oil.
2. Install the EN-43966-1 guides (1) into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install the EN-43953 compressor, the piston (2), and the connecting rod to the correct bore. 3.1. Stagger each piston ring end gap equally around the piston. 3.2. Lubricate the piston and the piston rings with engine oil. 3.3. Do not disturb the piston ring end gap location. 3.4. The piston must be installed so that the mark on the top of the piston faces the front of the engine. 3.5. Place the piston in its matching bore. 3.6. 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. 3.7. Hold the EN-43953 compressor against the engine block until all the rings have entered the cylinder bore. 3.8. Remove the connecting rod guides from the connecting rod bolt holes.
4. NOTE: Ensure that the connecting rod cap is properly oriented on the connecting rod. Install the connecting rod cap (1).
5. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Always use NEW bolts. Install NEW connecting rod bolts and tighten to 25 Nm (18 lb ft) plus 100 degrees using the EN-45059 angle 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 (LDK, LHU)

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 212

Scheme 213

Scheme 214

1. NOTE: Do not use any sealing material. Install the cylinder head gasket (2) to the block.
2. Install the cylinder head (1). 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. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Always use NEW cylinder head fastener. Install NEW cylinder head bolts. 3.1. Tighten the bolts in sequence to 30 Nm (22 lb ft) . 3.2. Tighten the bolts an additional 155 degrees in sequence using the EN-45059 angle meter.
4. Install the front cylinder head bolts (1) and tighten to 35 Nm (26 lb ft) .

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

1. Install the hydraulic lash adjusters (1) into their bores in the cylinder head. Apply lubricant to the lash adjusters, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
2. Lubricate the valve tips (1), refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
3. NOTE: Used roller followers must be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced. Position the roller followers (1) on the tip of the valve stem and on the lash adjuster. Apply lubricant to the followers, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
4. NOTE: The engine is timed top dead center exhaust stroke. When installing the camshafts, ensure 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 (1) on top of the roller followers in the camshaft bearing journals. Lubricate the camshaft, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
6. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12 o'clock 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 (1) and hand start the camshaft cap bolts (2).
9. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Lubricate and tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft cap bolts to 10 Nm (89 lb in) .
10. NOTE: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush. Ensure that all sealing material has been removed from the components, and the sealing surfaces are clean and free of contamination prior to applying the sealer. Install and align the rear cap within 20 minutes of applying the sealer. NOTE: Apply the sealer to all locations centrally locating the bead on the rail. Run bead to within 2.0 mm of the end points, dimension a, as shown. Where the cap ends on the perimeter rail, extend bead approximately 2.0 mm beyond edge of cap. Apply a 2.5 mm bead of sealer to the cylinder head at the exhaust camshaft bearing rear cap mating surface. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
11. Install the exhaust camshaft bearing rear cap and bolts. 11.1. Tighten the cap bolts equally to 5 Nm (44 lb in) . 11.2. Tighten the cap bolts equally to 10 Nm (89 lb in) . 11.3. Back the cap bolts out 120 degrees. 11.4. Tighten the cap bolts evenly a final pass to 10 Nm (89 lb in) .
12. Remove all excess sealing material from the power brake booster pump bore (1), and ensure the bore and gasket sealing surface is clean and free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Install the hydraulic lash adjusters (1) into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
3. Lubricate the valve tips (1).
4. NOTE: Used roller followers must be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced. Position the roller followers (1) on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
5. NOTE: The engine is timed top dead center exhaust stroke. When installing the camshafts, ensure 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 (1) on top of the roller followers in the camshaft bearing journals. Lubricate the camshaft, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
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. NOTE: The number 1 cylinder must be at top dead center (TDC), crankshaft keyway at the 12 o'clock position. Install the intake camshaft with the notch on the front at approximately the 5 o'clock position (1).
9. Install the camshaft caps (1) 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 cap to 10 Nm (89 lb in) .
11. NOTE: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush. Ensure that all sealing material has been removed from the components, and the sealing surfaces are clean and free of contamination prior to applying the sealer. Install and align the rear cap within 20 minutes of applying the sealer. NOTE: Apply the sealer to all locations centrally locating the bead on the rail. Run bead to 5.0 mm, dimension a, as shown. Where the cap ends on the perimeter rail, extend bead approximately 4.0 mm beyond edge of cap. Run bead, dimension c, 32 mm from the edge of the cylinder head as shown. Run beads, dimension b, 20 mm from edge of cylinder head as shown. Apply a 2.5 mm bead of sealer to the cylinder head at the intake camshaft bearing rear cap mating surface. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
12. Install the number 6 intake camshaft rear cap. 12.1. Tighten the cap bolts equally to 5 Nm (44 lb in) . 12.2. Tighten the cap bolts equally to 10 Nm (89 lb in) . 12.3. Back the cap bolts out 120 degrees. 12.4. Tighten the cap bolts evenly a final pass to 10 Nm (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. 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 Nm (89 lb in) .

Balance Shaft Installation

Special Tools

EN-43650 Balance Shaft Bushing Remover/Installer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 236

Scheme 237

Scheme 238

1. Install the balance shaft bushing (2) using the EN-43650 remover/installer (1).
2. Seat the balance shaft bushing into the bore using the EN-43650 remover/installer (1) and a wrench.
3. When the EN-43650 remover/installer is fully seated in the engine block, remove it with a wrench.
4. NOTE: If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise. 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. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the balancer shaft bolts and tighten to 10 Nm (89 lb in) .

Water Pump Installation (LDK, LHU)

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

Scheme 239

Scheme 240

Scheme 241

1. Install the water pump assembly (1) with a new gasket (2).
2. NOTE: Do not install the front water pump bolt until after the engine front cover is on. Install the water pump bolts. Finger tighten the bolts.
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Tighten the water pump bolts to 25 Nm (18 lb ft) .
4. Apply sealant to the water pump drain plug. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
5. Install the water pump drain plug and tighten to 20 Nm (15 lb ft) , if necessary.
6. Install the water feed tube (2).
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 (1) to block bolts and stud and tighten the thermostat housing bolts to 10 Nm (89 lb in) .
10. Install the coolant temperature sensor (1) by hand.
11. Tighten the coolant temperature sensor to 20 Nm (15 lb ft) .

Scheme 242

1. Install the balance shaft drive sprocket and key.
2. NOTE: If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. There are 3 colored links on the chain. 2 links are of matching colors, and 1 link is of a unique color. Use the following procedure to line up the links with the sprockets: Orient the chain so that the colored links are visible.
3. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
4. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket - approximately at the 6 o'clock position on the crank sprocket.
5. Place the chain (3) on the water pump drive sprocket. The alignment is not critical.
6. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.

Scheme 243

Scheme 244

Scheme 245

Scheme 246

1. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise. Install the upper balance shaft chain guide (1) and bolts and tighten to 12 Nm (106 lb in) .
2. Install the small balance shaft chain guide (1).
3. Install the balance shaft chain guide and bolts and tighten to 12 Nm (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 Nm (89 lb in) .
6. Reset the timing chain tensioner (1) by performing the following steps: 6.1. Turn the tensioner plunger 90 degrees in its bore and compress the plunger. 6.2. Turn the tensioner back to the original 12 o'clock position and insert a paper clip (2) 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 Nm (89 lb in) .
9. Remove the paper clip from the balance shaft drive chain tensioner.

Camshaft Timing Gear, Sprocket and Tensioner Installation (LDK, LHU)

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 (LDK, LHU) .

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

1. NOTE: The engine is timed top dead center exhaust stroke. 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. 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 the remaining friction washer (1), if equipped.
5. NOTE: There are 3 colored links on the timing chain. 2 links are of matching color, and 1 link is of a unique color. Use the following procedure to line up the links with the actuators. Orient the chain so that the colored links are visible. Always use new actuator bolts. Assemble the intake camshaft actuator into the timing chain with the time mark linked 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. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the adjustable timing chain guide (1) down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten the adjustable timing chain guide bolt to 10 Nm (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. NOTE: Always install NEW actuator bolts. Install the exhaust camshaft actuator (1) onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
14. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees 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 camshaft chain guide (1) and bolts and tighten to 12 Nm (106 lb in) .
18. Install the upper balance shaft chain guide (1) and bolts and tighten to 10 Nm (89 lb in) .
19. Reset the timing chain tensioner by performing the following steps: 19.1. Remove the snap ring. 19.2. Remove the piston assembly from the body of the timing chain tensioner. 19.3. Install the EN-45027-2 base (2) into a vise. 19.4. Install the notch end of the piston assembly into the EN-45027-2 base (2). 19.5. Using the EN-45027-1 tensioner (1), turn the ratchet cylinder into the piston. 19.6. Reinstall the piston assembly into the body of the tensioner. 19.7. 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. NOTE: Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak. NOTE: The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. The crankshaft balancer must be installed in order to release the tensioner. Install the timing chain tensioner assembly (1) and tighten to 75 Nm (55 lb ft) . Refer to «CRANKSHAFT BALANCER INSTALLATION (LDK, LHU)»(ref-653636-S00082146892014090100000) for tensioner release instructions.
23. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 Nm (89 lb in) . Using a torque wrench, tighten the camshaft actuator bolt to 30 Nm (22 lb ft), plus 100 degrees using the EN-45059 angle meter.
24. Using a torque wrench, tighten the camshaft actuator bolt to 30 Nm (22 lb ft), plus 100 degrees using the EN-45059 angle meter.
25. Remove EN-48953 locking tool.
26. Install the timing chain oil nozzle (1) and bolts and tighten to 10 Nm (89 lb in) .
27. Apply sealant to the thread of the timing chain guide bolt access hole plug (1). Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
28. Install the timing chain guide bolt access hole plug and tighten to 75 Nm (55 lb ft) .

Crankshaft Front Oil Seal Installation (LDK, LHU)

Special Tools

EN-34115 Sprocket Bearing Installer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 263

1. Install the seal (2) into the front cover using the EN-34115 installer (1).
2. Ensure that the engine front cover is properly supported when installing the seal.

Scheme 264

Scheme 265

Scheme 266

1. Install the engine front cover (1) with a new gasket (2).
2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: The center bolt (1) should be tightened last. Install the engine shield bolts and tighten to 25 Nm (18 lb ft) .
3. Install the long water pump bolt (1) and tighten to 25 Nm (18 lb ft) .
4. Install the accessory drive belt tensioner (1).
5. Install the accessory drive belt tensioner bolt and tighten to 45 Nm (33 lb ft) .

Scheme 267

Scheme 268

Scheme 269

1. NOTE: The lower crankcase surface must be free of contamination prior to applying the sealer. Install and align the oil pan to block within 20 minutes of applying the sealer. The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer. 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 (LDK, LHU)»(ref-653636-S40994991802014090100000) .
2. Install the oil pan (1).
3. Install the oil pan bolts and tighten the oil pan bolts in sequence to 25 Nm (18 lb ft) .

Scheme 270

1. Lubricate the oil level indicator tube O-ring, refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
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 to the intake manifold.
4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the oil level indicator tube bolts and tighten to 10 Nm (89 lb in) .
5. Install the electrical wiring harness to the oil level indicator tube.
6. Install the knock sensor wiring clip into the oil level indicator tube.

Scheme 271

1. NOTE: The oil cooler cannot be flushed or otherwise cleaned of contamination. Replace the oil cooler if a mechanical condition is suspected that could cause the oil cooler to be contaminated. Install the oil cooler (1).
2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the oil sump bolts (2) and tighten to 25 Nm (18 lb ft) .

Engine Flywheel Installation (Automatic Transmission)

Special Tools

1. EN-43653 Flywheel Holding Tool
2. EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 272

1. Install the flywheel (1) for automatic transmission.
2. Install the NEW bolts.
3. Install EN-43653 flywheel holding tool in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
4. Tighten the flywheel bolts to 53 Nm (39 lb ft) plus 25 degrees using the EN-45059 angle meter.
5. Remove EN-43653 flywheel holding tool.

Crankshaft Balancer Installation (LDK, LHU)

Special Tools

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

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 273

Scheme 274

Scheme 275

1. WARNING: Ensure both components are aligned correctly or serious engine damage will occur. Install the balancer (2) onto the EN-48585 guide (1). Use care to properly align the keyway and flats on the balancer with the oil pump drive.
2. Install the crankshaft balancer into the end of the crankshaft.
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: EN-43653 flywheel holding tool may be used instead of EN-38122-A crankshaft balancer holder to prevent crankshaft rotation. NOTE: Always install a NEW crankshaft balancer retaining bolt. Install a NEW retaining bolt. Use EN-38122-A holder (1) and a breaker bar to prevent the crankshaft from rotating, and tighten the bolt to 100 Nm (74 lb ft) plus 125 degrees using the EN-45059 angle meter.
4. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 Nm (89 lb in) .
5. Release the timing chain tensioner by applying 45 Nm (33 lb ft) counterclockwise torque to the crankshaft balancer bolt.
6. Remove EN-48953 locking tool.

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

1. Install NEW camshaft cover grommets and camshaft cover bolts if they are serviced with the grommets.
2. Assemble the camshaft cover (1) and 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.
4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the ignition coils (4). Tighten the ignition coil bolts (3) to 10 Nm (89 lb in) .
5. Tighten the camshaft cover bolts to 10 Nm (89 lb in) .
6. NOTE: The solenoid valves are marked intake and exhaust. Install the camshaft position actuator solenoid valves (2).
7. Install the camshaft position setting-valve bolts (1) and tighten to 10 Nm (89 lb in) .
8. Install the camshaft housing cover insulator (1) and bolts. Tighten the camshaft cover's insulator bolts to 10 Nm (89 lb in) .
9. Install the front lift bracket (1).
10. Install the engine lift-bracket front bolts and tighten to 25 Nm (18 lb ft) .
11. Install the power brake booster pump NEW O-ring seal (1).
12. NOTE: Ensure that the exhaust camshaft slotted insert is aligned with the power brake booster pump. Install the power brake booster pump (2).
13. Install the brake servo pump bolts and tighten to 22 Nm (16 lb ft) .
14. Install the rear lift bracket (1).
15. Install the engine lift-bracket rear bolts and tighten to 25 Nm (18 lb ft) .

Oil Filter with Cap and Seal Installation

Special Tools

EN-44887 Oil Filter Spanner

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 282

1. Install a new oil filter (2) on the oil filter cap (1).
2. Lubricate the oil filter cap O-ring with engine oil. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Use the EN-44887 wrench to install the oil filter and cap. Tighten the oil filter and cap to 22 Nm (16 lb ft) .

Fuel Rail and Injector Installation (LDK, LHU)

Special Tools

1. EN-47909 Injector Bore and Sleeve Cleaning Kit
2. EN 48896 HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

1. Clean the injector bore in the cylinder head using the EN-47909 cleaning kit.
2. Install the fuel rail with the fuel injectors into the cylinder head evenly.
3. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.
4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Start and hand tighten the remaining fuel rail bolts. 4.1. Tighten the fuel rail bolts in sequence to 22 Nm (16 lb ft) . 4.2. Tighten the fuel rail bolts in sequence a second time to 22 Nm (16 lb ft) .
5. Install the fuel injector noise insulator (1).
6. Connect the electrical harness to the fuel rail harness connection.
7. NOTE: The camshaft must be in the base circle position before the high pressure fuel pump is installed. 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. NOTE: Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle, and the number 1 piston is at top dead center (TDC) on the exhaust stroke. The distance from the mounting flange surface to the camshaft at base circle should be 52 mm (2.05 in). Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.
10. Install a NEW high pressure fuel pump gasket (1).
11. Install a NEW high pressure fuel pump O-ring (2).
12. NOTE: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing. Install the high pressure fuel pump (3).
13. Start and hand-tighten the high pressure fuel pump bolts evenly.
14. Tighten the high pressure fuel pump bolts evenly to 15 Nm (11 lb ft) .
15. Install and hand-tighten both ends of the NEW high pressure fuel line (1).
16. Tighten the high pressure fuel line fitting nuts to 30 Nm (22 lb ft) .

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

1. Install a NEW intake manifold gasket (1).
2. Install the intake manifold (2).
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the intake manifold bolts and nuts (3) finger tight.
4. Tighten the intake manifold bolts and nuts in sequence: 4.1. Tighten the intake manifold bolts to 25 Nm (18 lb ft) . 4.2. Tighten the intake manifold nuts to 22 Nm (16 lb ft) .
5. Install the EVAP purge solenoid valve (4) and bolt (3). Tighten the bolt to 4 Nm (35 lb in) .
6. Install the MAP sensor (2) and bolt (1). Tighten the bolt to 4 Nm (35 lb in) .
7. Install the intake manifold brace (2).
8. Install the intake manifold brace bolt (1) and nut (3) and tighten to 25 Nm (18 lb ft) .
9. Connect the rear knock sensor to the intake manifold brace.
10. Install the throttle body (1).
11. Install the throttle body bolts (2) and tighten to 10 Nm (89 lb in) .
12. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
13. Install the fuel feed line. (2)
14. Install the fuel feed line bolts.
15. Connect the low pressure fuel line nut (1) and tighten to 30 Nm (22 lb ft) .
16. Tighten the fuel line bolts to 10 Nm (89 lb in) .
17. Install the high pressure fuel pump noise insulator (1).
18. Install the high pressure fuel pump cover (2).
19. Install the HP fuel pump cover bolts and tighten to 10 Nm (89 lb in) .
20. Install the charger AIR bypass valve solenoid (1) with charger AIR bypass tube assemblies.
21. Install the charger (AIR) bypass valve solenoid bolts and tighten to 10 Nm (89 lb in) .
22. NOTE: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. Connect the charger AIR bypass tube assemblies and clips from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
23. Install the charger AIR bypass valve tank assembly (1).
24. Tighten the charger AIR bypass valve tanks assembly bolt to 25 Nm (18 lb ft) .
25. Install the charger (AIR) bypass valve tank unit nut (2) and tighten to 25 Nm (18 lb in) .
26. NOTE: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. The tube with retaining clamp located on the charger AIR bypass valve tank assembly left side connects to the charger AIR bypass valve solenoid. The right side, permanently attached tube connects to the intake manifold. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.
27. Connect the final charger AIR Bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.

Scheme 298

Scheme 299

Scheme 300

Scheme 301

1. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install new exhaust manifold studs (1) and tighten to 15 Nm (11 lb ft) .
2. Install the exhaust manifold gasket (2).
3. Install the exhaust manifold (1) to the cylinder head.
4. NOTE: Install the Torx® nut (3) in the correct location. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. NOTE: Use an inverted Torx® socket E16 to tighten the Torx® nut. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. 5.1. Tighten the exhaust pipe nuts to 14 Nm (10 lb ft) . 5.2. Tighten the exhaust manifold nuts a second time to 14 Nm (10 lb ft) .
6. Install the exhaust manifold heat shield (1).
7. Install the exhaust manifold heat shield bolts and tighten to 25 Nm (18 lb ft) .

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

1. Install a new turbocharger oil return pipe gasket (1).
2. Install the turbocharger oil return pipe (2) on the turbocharger.
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the turbocharger oil return hose bolts (3) and tighten to 10 Nm (89 lb in) .
4. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.
5. Install the PCV hose fitting bolt and tighten to 10 Nm (89 lb in) .
6. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
7. Install a new turbocharger gasket (3).
8. Install the turbocharger (2) with the oil return pipe.
9. Install the turbocharger nuts (1). 9.1. Tighten the turbocharger nuts to 30 Nm (22 lb ft) . 9.2. Tighten the turbocharger nuts a second time to 35 Nm (26 lb ft) .
10. Install the turbocharger brace (1).
11. Install the turbocharger stay nuts and tighten to 50 Nm (37 lb ft) .
12. Install the catalytic converter bracket (1).
13. Install the catalytic converter bolts and tighten to 50 Nm (37 lb ft) .
14. Install the turbocharger coolant feed pipe (1).
15. Install the turbocharger coolant feed pipe gaskets.
16. Install the turbocharger coolant feed pipe bolts. 16.1. Tighten the bolts of the turbocharger coolant delivery pipe to 35 Nm (26 lb ft) . 16.2. Tighten the turbocharger coolant feed pipe mounting bolt to 10 Nm (89 lb in) .
17. Connect the positive crankcase ventilation (PCV) and hose assembly.
18. Install the turbocharger air cooler outlet pipe (1).
19. Install the turbocharger air-cooler outlet pipe bolts and tighten to 25 Nm (18 lb ft) .
20. WARNING: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation. NOTE: The engine block end of the oil feed pipe fitting has an anti-rotation feature. Ensure that the fitting is fully seated against the block when installing the bolt. Install the turbocharger oil feed pipe (1) on the engine block side.
21. Install the turbocharger oil feed pipe gasket on the engine block side.
22. Install the bolt and tighten to 40 Nm (30 lb ft) .
23. Install the turbocharger coolant return pipe (1).
24. Install the turbocharger coolant return pipe gaskets.
25. Install the turbocharger coolant return pipe bolts and tighten to 35 Nm (26 lb ft) .
26. WARNING: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation. Install the turbocharger oil feed pipe (1) onto the turbocharger.
27. Install the turbocharger oil feed pipe gasket for the turbocharger side.
28. Install the turbocharger oil feed pipe bolt and tighten to 40 Nm (30 lb ft) .
29. Install the catalytic converter L-bracket (2) onto the catalytic converter (1).
30. Install the catalytic converter L-bracket nuts and tighten to 50 Nm (37 lb ft) .
31. Install the catalytic converter seal (2).
32. Install the catalytic converter (1).
33. Install the catalytic converter nuts and tighten to 50 Nm (37 lb ft) .
34. Install the catalytic converter bolts and tighten to 50 Nm (37 lb ft) .
35. Install the turbocharger heat shield (1).
36. Install the turbocharger heat shield bolts and tighten to 10 Nm (89 lb in) .

Scheme 314

1. Install the starter (1).
2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the starter motor bolts and tighten to 53 Nm (39 lb ft) .

1. Install the «engine in a stand»(ref-653636-S10385009112014090100000)
2. Remove the «engine oil cooler»(ref-653636-S18347503282014090100000) (LDK, LHU)
3. Drain fluids and remove the «oil filter»(ref-653636-S09807857992014090100000)
4. Remove the crankshaft «balance weight»(ref-653636-S08925127202014090100000)
5. Remove the engine «flywheel»(ref-653636-S18788604402014090100000) (automatic gearbox)
6. Remove the «OIL DIPSTICK»(ref-653636-S17514318162014090100000) and tube (LDK, LHU)
7. Remove the «STARTER»(ref-653644-S07228639072014090100000) motor (LDK, LHU)
8. Remove the intake manifold (LDK, LHU)
9. Remove the fuel rail and injectors (LDK, LHU)
10. Remove the turbocharger (LDK, LHU)
11. Remove the exhaust manifold (LDK, LHU)
12. Remove the camshaft cover (LDK, LHU)
13. Remove the engine front cover and oil pump
14. Remove the timing chain and tensioner (LDK, LHU)
15. Remove the intake and exhaust camshaft, bearing caps and valve clearance adjuster (LDK, LHU)
16. Remove the water pump, balancer shaft chain and tensioning device
17. Remove the balancer shaft
18. «REMOVE THE WATER PUMP (LDK, LHU)»(ref-653636-S01104106622014090100000)
19. «REMOVE THE CYLINDER HEAD (LDK, LHU)»(ref-653636-S39835010992014090100000)
20. «REMOVE THE OIL PAN (LDK, LHU)»(ref-653636-S20425900702014090100000)
21. Remove the piston, connecting rod and bearing (LDK, LHU)
22. Remove the lower crankcase
23. «REMOVE THE CRANKSHAFT AND BEARING»(ref-653636-S00640058332014090100000)
24. Remove the cylinder block (LDK, LHU)

1. Clean and inspect the cylinder block
2. Hone the cylinder
3. Remove the cylinder liner
4. Install the cylinder liner
5. Clean and check the crankshaft «balance weight»(ref-653636-S08925127202014090100000)
6. Clean and check the engine «flywheel»(ref-653636-S18788604402014090100000)
7. Clean and check the crankshaft and bearing
8. Remove the piston and connecting rod (LDK, LHU)
9. Clean and check the piston, connecting rod and bearing (LDK, LHU)
10. Install the piston and connecting rod (LDK, LHU)
11. Clean and check the camshaft (LDK, LHU)
12. Clean and check the timing chain and sprocket (LDK, LHU)
13. Clean and check the balancer shaft
14. «CLEAN AND CHECK THE WATER PUMP AND BALANCER SHAFT CHAIN AND SPROCKET (LDK, LHU)»(ref-653636-S02393057762014090100000)
15. «REMOVE THE CYLINDER HEAD (LDK, LHU)»(ref-653636-S39835010992014090100000)
16. Clean and check the cylinder head (LDK, LHU)
17. Grind the valves and seats
18. Install the cylinder head (LDK, LHU)
19. «REMOVE THE OIL DIPSTICK»(ref-653636-S17514318162014090100000)
20. Install the oil pump
21. Clean and inspect the turbocharger (LDK, LHU)
22. Clean and check the fuel rail and injectors (LDK, LHU)
23. Clean and inspect the intake manifold (LDK, LHU)
24. Clean and inspect the exhaust manifold (LDK, LHU)
25. Clean and check the oil pan (LDK, LHU)
26. Repair the threads
27. «SERVICE PRIOR TO ASSEMBLY»(ref-653636-S21322508292014090100000)

1. Install the engine block (LDK, LHU). See «Cylinder Block Cleaning and Check (LDK, LHU)»(ref-653636-S29751507642014090100000)
2. Install the crankshaft and bearing. See «Crankshaft and Bearing Removal»(ref-653636-S00640058332014090100000)
3. Install the crankcase (LDK, LHU). See «Lower Crankcase Installation (LDK, LHU)»(ref-653636-S01442591942014090100000)
4. Install the rear crankshaft seal. See «Crankshaft Rear Oil Seal Installation»(ref-653636-S35054377062014090100000)
5. Install the piston, connecting rod and bearing (LDK, LHU). See «Piston, Connecting Rod and Bearing Installation (LDK, LHU)»(ref-653636-S09704967022014090100000)
6. Install the cylinder head (LDK, LHU). See «Cylinder Head Installation (LDK, LHU)»(ref-653636-S35703052692014090100000)
7. Install the intake and exhaust camshaft, bearing caps and valve clearance adjuster (LDK, LHU). See «Intake and Exhaust Camshaft, Bearing Cap and Valve Clearance Adjuster (LDK, LHU)»(ref-653636-S01859114812014090100000) Installation
8. Install the balancer shaft. See «Balance Shaft Installation»(ref-653636-S42799978162014090100000)
9. Install the water pump (LDK, LHU). See «Water Pump Installation (LDK, LHU)»(ref-653636-S19038060882014090100000)
10. Install the balancer shaft to engine timing (LDK, LHU). See «Balance Shaft to Engine Timing (LDK, LHU)»(ref-653636-S06062878982014090100000)
11. Install the water pump, balancer shaft chain and tensioning device. See «Water Pump and Balance Shaft Chain and Tensioner Installation»(ref-653636-S25284379472014090100000)
12. Install the camshaft timing chain, sprocket and tensioner (LDK, LHU). See «Camshaft Timing Gear, Sprocket and Tensioner Installation (LDK, LHU)»(ref-653636-S00032627322014090100000)
13. Install the crankshaft front oil seal (LDK, LHU). See «Crankshaft Front Oil Seal Installation (LDK, LHU)»(ref-653636-S26675220662014090100000)
14. Install the engine front cover and oil pump. See «Engine Front Cover and Oil Pump Installation»(ref-653636-S09798043692014090100000)
15. Install the oil pan (LDK, LHU). See «Oil Pan Installation (LDK, LHU)»(ref-653636-S00933355562014090100000)
16. Install the oil level indicator and pipe (LDK, LHU). See «Oil Level Indicator and Pipe Installation (LDK, LHU)»(ref-653636-S23319831662014090100000)
17. Install the engine oil cooler (LDK, LHU). See «Engine Oil Cooler Installation (LDK, LHU)»(ref-653636-S38253251112014090100000)
18. Install the engine «flywheel»(ref-653636-S18788604402014090100000) (automatic gearbox)
19. Install the crankshaft balancer (LDK, LHU). See «Crankshaft Balancer Installation (LDK, LHU)»(ref-653636-S00082146892014090100000)
20. Install the camshaft cover (LDK, LHU). See «Camshaft Cover Installation (LDK, LHU)»(ref-653636-S25529205492014090100000)
21. Install the oil filter with cover and seal. See «Oil Filter with Cap and Seal Installation»(ref-653636-S00788426962014090100000)
22. Install the fuel rail and injectors (LDK, LHU). See «Fuel Rail and Injector Installation (LDK, LHU)»(ref-653636-S07005636722014090100000)
23. Install the intake manifold (LDK, LHU). See «Intake Manifold Installation (LDK, LHU)»(ref-653636-S30475588442014090100000)
24. Install the exhaust manifold (LDK, LHU). See «Exhaust Manifold Installation (LDK, LHU)»(ref-653636-S11187893422014090100000)
25. «INSTALL THE TURBOCHARGER (LDK, LHU)»(ref-653636-S15266625592014090100000)
26. «INSTALL THE STARTER MOTOR (LDK, LHU)»(ref-653636-S39321120312014090100000)
27. Prelube the engine. See «Engine Prelubing»(ref-653636-S13067371132014090100000)

Scheme 315