Page 556 of 2490

5.
Install the front cros smember. Refer to Operat
ion 76.10.05.
6. Install the undert ray. Refer to Operation 76.22.90.
7. Install both front wheel and tyre assemblies. Refer to
Operation 74.20.05.
8. Install the timing cover and al l associated components, as
detailed in Operation 12.65.01.
9. Install the twin fan and motor assembly. Refer to Operation
26.25.12.
10. NOTE: When the engine is star ted from cold and run for a
short period only, before being swit ched off, a quantity of oil will
be 'hung up' within the engine because it is not up to operating
temperature.
Should the oil level subsequently be topped-up, the level could
become too high, causing oil burning.
Typically, 0.875 L is hung up.
Refill the engine with the correct specification engine oil.
11. Connect the battery and in stall the battery cover.
Refe
r to the Battery Reconnection Procedure 86.15.15.
12. Check the oil level and start th e engine. Check for leaks and
that the engine runs correctly.
13. Install the engine compartmen t cover. Refer to operation
76.16.01.
14. Remove the paintwork protection sheets and close the engine
compartment cover.
Page 584 of 2490

13. Tigh
ten the exhaust camshaft
sprocket securing bolt.
1. Install the chain tensioner tool 303-532 to the sprocket holes.
Appl y force
to the tool in an
anti-clockwise direction to
tension the chain on its drive side.
2. Whilst applying the opposing force to the sprocket and chain, tighten the sprock et securing bolt to 115-
125 Nm.
14 .
Tigh
ten the intake camshaft
sprocket securing bolt.
1. Whilst still applying the opposing force to the
sprocket and chain (using 303-532), check that the
wedges are still in place, ti ghten the securing bolt to
115-125 Nm.
R e
move the chain tensioning
tool and the wedge(s).
15. Remove the camshaft locking tool 303-530.
16. Raise the vehicle on the ramp.
17. Remove the crankshaft setting tool 303-531.
18 . Inst
all the crankshaft position sensor.
1. Install the sensor to the flywheel housing and install
the securing bolt. Tighten to 6-8 Nm.
2. Install the access grommet to the housing.
19. Lower the ramp.
20. Install the Timing Cover. Refer to Operation 12.65.01.
21. Move the engine compartment cover from the service position
and connect the gas struts.
22. Remove the paint protection sheets and close the cover.
Page 592 of 2490
2.
Fit a new O-ring to the carrier oil-way.
14. F
it the VVT bush carrier to the cylinder block.
Lubric
ate the seal (scarf
jointed) and the bush.
1. Fit the bush carrier assembly.
Check that th e seals are in pl ace an
d that the ring dowels
are engaged squarely. Fully locate the assembly as much
as possible by hand pressure.
2. Fit the three securing bolts. Tighten to 19-23 Nm.
15. Refit the Timing Cover. Refer to Operation 12.65.01 in this
Section.
16. Move the engine compartment cover from the service position
and connect the gas struts.
17. Remove the paint protection sheets and close the cover.
18. Connect the battery and fit the battery cover.
Refe
r to the Battery Reconnection Procedure in Section
414-01.
Page 607 of 2490

3.
F
it the tool to the crankshaft.
E
nsure that the cent
re bolt is unscrewed to below the face
which is to fit to the crankshaft and position the tool to the
crankshaft.
Chec
k that the nuts are fully unscrewed and enter the two
bolts to the crankshaft thre ads and lightly tighten.
4. Tigh
ten the nuts, finger tight, to hold the tool assembly against
the seal. Check that the seal and the tool are approximately
parallel to the rear of the engine.
5. Pres
s the seal into the housing.
Ho
ld each bolt stationary, in
turn, and tighten its nut a
small amount (approximately two to three flats) in turn, to
press the seal fully into the housing. until the tool is in
contact with the cylinder block.
6. Remove the tool from the crankshaft.
Chec
k that the seal is located correctly.
7. Fit the drive plate. Refer to Operation 12.53.13.
8. Install the transmission. Refer to Operation 44.20. 01 in
Section 307-01A.
9. Remove the paint protection sheets and close the engine
compartment cover.
10. Connect the battery and fit the battery cover.
Re
fer to the Battery Reconnection Procedure 86.15.15.
Page 610 of 2490

3.
Fit
the tool to the crankshaft.
En
sure that the cent
re bolt is unscrewe d to below the face
which is to fit to the crankshaft and position the tool to the
crankshaft.
Chec k that
the nuts are fully unscrewed and enter the two
bolts to the crankshaft thre ads and lightly tighten.
4. Tight
en the nuts, finger tight, to hold the tool assembly against
the seal. Check that the seal and the tool are approximately
parallel to the rear of the engine.
5. Pres s th
e seal into the housing.
Ho
ld e
ach bolt stationary, in
turn, and tighten its nut a
small amount (approximately two to three flats) in turn, to
press the seal fully into the housing. until the tool is in
contact with the cylinder block.
6. Remove the tool from the crankshaft.
Chec k that
the seal is located correctly.
7. Fit the drive plate. Refer to Operation (SC) 12.53.13.
8. Install the transmission. Refer to Operation 44.20. 01 in
Section 307-01B.
9. Remove the paint protection sheets and close the engine
compartment cover.
10. Connect the battery and fit the battery cover.
Re
fe
r to the Battery Reconnection Procedure 86.15.15.
Page 633 of 2490

I
dentify the VCT oil supply gallery and the 8 mm blind rivet.
U
sing a suitable 3 mm punch release the centre of the blind rivet until
it is released from the outer part of the blind rivet.
U
sing a suitable extraction tool, remo
ve the remaining part of the blind
rivet.
2. Clean the component mating faces.
3.
Check cylinder head face for distortio
n, across the center and from corner
to corner.
4. For cylinder head face distortion data, refer to specifications.For additional
information, refer to: Specifications
(303
-00 Engine System - General
Information, Specifications).
5.
NOTE: For
cylinder head with
distortion above the
maximum allowance,
the cylinder head
material must be
measured.
Measure the
cylinder head
material.
Che
ck
measurement
from the
centre of the
exhaust
dowel to the
cylinder head
face as
shown.
If the
measurement
is less than
51.88 mm
the cylinder
head requires
replacement.
6.
Install a new gasket to the downpipe catalyst flange.
7. Install and align a new cylinder head gasket to the cylinder block face.
Page 646 of 2490
In
stallation
27
. Clean all parts and mating faces.
1. Fit ne
w seals to the timing cover.
1. Fit and fully locate, a new seal to the inner groove on the face of the timing cover.
2. Fit and fully locate, a new seal to the outer groove on the face of the timing cover.
Re
move the transit ring and check that the oil seal is not
damaged.
2. Appl y s
ealant to the eight joints on the engine face.
Sealant
beads to be 3mm di ameter an
d 12mm long. Cut
the nozzle of the sealant tube to produce a 3mm bead.
(Fit and tighten the securing bolts within twenty minutes
of sealant application)
3. Re
fit the timing cover, step 1.
Lo
wer th
e cover into the engine compartment, to its
approximate position.
4. Refit the timing cover, step 2.
Stan din
g at the right hand side
of the vehicle, rotate and
manoeuvre the cover downwards to clear the water pump
Page 717 of 2490
25. Reconnect the air flow meter multi-plug.
26. fit a new strap to secures the vacuum pipe to the induction
elbow.
27. Connect the breather pipe to the A-Bank camshaft cover.
1. Fit a new O-ring seal to the breather pipe.
2. Reconnect the breather pipe to the stub pipe.
28. Carefully refit the engine covers, taking care not to damage
the plastic fixings or the rubber inserts.
29. Connect the battery ground cabl e. Refit the battery cover.
Reset the clock and the radio information.
30. Check for leaks and that all pi pes are securely connected.
Remove the protection sheets, close the engine compartment,
luggage compartment and doors.