Part 2

Engine

Assembly

50. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).

51. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.

Verify the timing with these steps.
1 There should be 12 chain links between the camshaft timing marks.
2 There should be 27 chain links between the camshaft and the crankshaft timing marks.
3 There should be 30 chain links between the camshaft and the crankshaft timing marks.





52. Remove the crankshaft damper bolt.





53. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).

Install the ignition pulse wheel.





54. Install 3 new gaskets in the front cover.

55. NOTE: Clean and degrease the sealing surfaces with metal surface cleaner before applying gasket and sealant.

NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 6 mm (0.24 inch) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.





56. NOTE: Fasteners 1, 8, 13 and 16 are stud bolts.

Position the front cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 25 Nm (18 ft. lbs.)





57. Install the belt tensioner and the bolt.
^ Tighten to 45 Nm (33 ft. lbs.)





58. Install the idler pulley and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.)





59. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.

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





60. NOTE: Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealant.

NOTE: Sealing surfaces must be free of dirt and oil.

NOTE: The crankshaft damper must be installed and the bolt tightened within 4 minutes of sealant application.

Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.





61. NOTE: Lubricate the outside diameter sealing surface with clean engine oil.

Using the special tool, install the crankshaft vibration damper.





62. Install the crankshaft vibration damper washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs.)
^ Stage 2: Loosen one full turn (360°.)
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.)
^ Stage 4: Tighten to 90 Nm (66 ft. lbs.)





63. Install the knock sensor (KS) and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.)





64. Install the oil pressure sender and, if equipped, the block heater.
^ Tighten to 14 Nm (10 ft. lbs.)





65. Position the oil pan baffle. Install the nuts and tighten in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.)
^ Stage 2: Tighten 45°.





66. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.





67. Install the oil pump screen and pickup tube.
1 Position the oil pump screen and pickup tube.
2 Install the bolts.
3 Install the nut and tighten in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.)
^ Stage 2: Tighten 45°.





68. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.





69. Position the oil level indicator and tube and install the stud bolt.
^ Tighten to 10 Nm (89 inch lbs.)





70. Install the bypass tube and the nut and bolt.
^ Tighten to 10 Nm (89 inch lbs.)





71. Position the coolant tube and connect the hoses.





72. Install the coolant pump and the bolts.
^ Tighten to 10 Nm (89 inch lbs.)





73. Connect the hoses.





74. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.





75. CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.

Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.

76. Lubricate the O-ring seal and install the oil filter.
^ Tighten the oil filter 3/4 of a turn after the filter gasket makes contact with the oil filter adapter.





Front wheel drive (FWD) vehicles

77. Install the halfshaft support bracket and the bolts.
^ Tighten to 48 Nm (35 ft. lbs.)





78. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.)





79. Install a new gasket and the RH exhaust manifold and new nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs.)





All vehicles

80. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.)





81. Install a new gasket and the LH exhaust manifold and new nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs.)





82. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install the LH and RH spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.)





83. NOTE: LH shown, RH similar.

NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.

NOTE: Clean cylinder head and front cover surface using metal surface cleaner before applying silicone gasket and sealant.

Apply an 8 mm (0.31 inch) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.





84. NOTE: Install a new valve cover gasket.

Position the LH valve cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.)