Part 3
EngineAssembly (Steps 57-84)
57. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
58. Using the special tools, install the crankshaft front oil seal into the engine front cover.
59. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
60. Using the special tool, install the crankshaft pulley.
61. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 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.
62. NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
Slide the coolant tube forward with the new O-ring seals into the cylinder block.
63. Install the coolant tube stud bolt.
^ Tighten to 10 Nm (89 inch lbs.).
64. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
Position the coolant pump and install the 4 bolts loosely.
65. Tighten the 4 coolant pump bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
66. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
67. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
68. Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
69. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
70. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
71. Install the knock sensor (KS) and the bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
72. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
73. NOTE: If not secured within 4 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 2 places where the engine front cover meets the cylinder head.
74. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the RH valve cover and gasket on the cylinder head and tighten the 14 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
75. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
76. NOTE: If not secured within 4 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 2 places where the engine front cover meets the cylinder head.
77. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the LH valve cover and gasket on the cylinder head and tighten the 15 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
78. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
79. Install the RH motor mount bracket, 2 bolts and 2 stud bolts.
^ Tighten to 55 Nm (41 ft. lbs.).
80. Install the oil level indicator tube and the bolt.
^ Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 inch lbs.).
81. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
82. Install the LH motor mount bracket and 4 bolts.
^ Tighten to 55 Nm (41 ft. lbs.).
83. 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.
NOTE: Clean and inspect the mating surfaces and install new gaskets.
Position the oil filter adapter and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
84. Install a new oil filter.