Part 2

Engine

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material (Part 1):

Material (Part 2):

Engine - Upper End (Part 1):

Engine - Upper End (Part 2):

Engine Induction System (Part 1):

Engine Induction System (Part 2):

Engine Lower End (Part 1):

Engine Lower End (Part 2):

Engine Front End (Part 1):

Engine Front End (Part 2):

Assembly (Steps 49-95)
49. Repeat the previous 2 steps for each camshaft roller follower.

50. 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: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

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 onto the dowels. Install the fasteners finger-tight.





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











53. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





54. 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.

Install the coolant pump.
1 Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
2 Position the coolant pump into the engine block.
3 Install the bolts.
^ Tighten to 25 Nm (18 lb-ft).





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





56. Using the special tools, install a new crankshaft front seal into the engine front cover.





57. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 on the crankshaft pulley.





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





59. Tighten the new crankshaft pulley bolt in 4 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.





60. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
^ Tighten to 25 Nm (18 lb-ft).





61. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).





62. 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.

Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
63. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.





64. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 in 2 places where the engine front cover meets the cylinder head.





65. Position the LH valve cover and gasket and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).











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





67. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 in 2 places where the engine front cover meets the cylinder head.





68. Position the RH valve cover and gasket and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).











69. NOTE: Lubricate the O-ring seal with clean engine oil.

Install the oil level indicator tube.
^ Install a new O-ring seal on the oil level indicator tube.
^ Install the oil level indicator tube.
^ Install the bolt.
^ Tighten to 10 Nm (89 lb-in).





70. Install 8 new LH exhaust manifold-to-cylinder head studs.
^ Tighten to 12 Nm (9 lb-ft).





71. Install the new LH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





72. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 lb-ft).





73. NOTE: Do not reuse the O-ring seal.

NOTE: Lubricate the O-ring seal with clean engine coolant.

Slide the heater outlet tube forward with the new O-ring seal into the cylinder block.





74. Install the heater outlet tube studs.
^ Tighten to 25 Nm (18 lb-ft).





75. Connect the coolant hoses to the heater outlet tube.





76. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
77. Connect the RH radio ignition interference capacitor electrical connector.





78. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.





79. Connect the engine oil pressure (EOP) switch electrical connector.





80. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.





81. Connect the (CMP) sensor electrical connectors.





82. Install the special tool.





83. Using a suitable floor crane, remove the engine from the engine stand.

84. 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 crankshaft 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.

85. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer plate mating surface on the engine block.

Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block.





86. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.





87. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





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 not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.





90. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 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 3 stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
^ Stage 3: Tighten an additional 60 degrees.





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

Using the special tools, install a new crankshaft rear seal.





94. Using the special tools, install a new crankshaft rear oil slinger.





95. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 80 Nm (59 lb-ft).