Part 2

49. Install the crankshaft sensor ring on the crankshaft.






50. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause Ititure oil leakage.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.






51. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.






52. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).










53. Position the belt idler pulley and install the bolt.






54. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.






55. Use the special tools to install the crankshatt front oil seal into the engine front cover.






56. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause tature oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.






57. Use the special tool to install the crankshaft pulley.






58. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.

Tighten the new crankshafl pulley bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.






59. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.






60. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause fliture oil leakage.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.






61. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.






62. Tighten the bolts in the sequence shown.






63. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.






64. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause fliture oil leakage.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.






65. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.






66.T ighten the bolts in the sequence shown.






67. Install the crankcase ventilation tube on the LH valve cover.






68. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the hose support.






69. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.

70. Connect the CKP sensor electrical connector






71. Connect the knock sensor electrical connector.

72. Connect the RH radio frequency interference capacitor electrical connector.






73. Connect the CMP sensor electrical connector.






74. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.






75. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.






76. NOTE: Clean and inspect the mating surfaces, and install new gaskets.

Position the oil filter adapter and install the four bolts.






77. Position the LH engine mount to the cylinder block and install the bolts.






78. Position the RH engine mount to the cylinder block and install the bolts.






79. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the 0-ring seal will occur.

Install the coolant pump.
1. Lubricate the new 0-ring seal with engine coolant and install the 0-ting seal onto the coolant pump.
2. Position the coolant pump into the engine block.
3. Install the bolts.






80. Position the coolant pump pulley on the coolant pump and install the bolts.






81. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.






82. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause filture oil leakage.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.

83. Install the rear oil seal retainer plate and loosely install the six bolts.






84. Tighten the bolts in the sequence shown.






85. Install the oil drain plug.






86. Install the oil pump screen and piclcup tube spacer.






87. CAUTION: Make sure the 0-ring is in place and not damaged. A missing or damaged 0-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new 0-ring. Lubricate the 0-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the bolts.






88. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

89. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.






90. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause filture oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.






91. Install the oil pan gasket and the oil pan and loosely install the bolts.






92. Tighten the bolts in two stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.






93. Install the special tool.






94. Install the special tool.






95. Install the special tool and remove the engine from the work stand.






96. Lower the engine onto wooden blocks.

97. Remove the special tool.






98. Remove the special tool.






99. Install the special tool and raise the engine.






100. Install the power steering reservoir lower mounting bracket.






101. NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.

Using the special tools, install a new crankshafi rear oil seal






102. Using the special tools, install the crankshaft rear oil slinger.






103. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.






104. Install the engine.