Steps 41-78

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





42. Using the special tools, install the crankshaft front seal.





43. 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 future oil leakage.

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





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





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

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





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





47. NOTE: The front lower hole in the power steering pump is not used.

Position the power steering pump and install the bolts.





48. Apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.





49. 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 future oil leakage.

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





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





51. Tighten the bolts in the sequence shown.





52. Apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.





53. 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 future oil leakage.

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





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





55. Tighten the bolts in the sequence shown.





56. Position the oil level indicator tube.





57. Install the bolt attaching the oil level indicator tube to the rear of the engine.





58. Install the nut attaching the oil level indicator tube to the front of the engine.





59. Connect the crankcase vent tube to the valve cover.





60. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors.
61. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.





62. Connect the Crankshaft Position (CKP) sensor electrical connector.





63. Connect the oil pressure switch electrical connector.





64. Connect the knock sensor electrical connector, if equipped.





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





66. Connect the Camshaft Position (CMP) sensor electrical connector.





67. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





68. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
69. Install the RH engine mount.
^ Tighten the bolts to 63 Nm (46 ft. lbs.).





70. Install the special tool.





71. Install the special tool.





72. Install the special tool and remove the engine from the work stand.
73. Lower the engine onto wooden blocks.





74. Remove the special tool.





75. Remove the special tool.





76. Install the special tool and raise the engine.





77. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence shown.
78. Install the engine.