Steps 51-97

Engine


















Engine - Upper End














Engine - Lower End














Engine - Front End









51. NOTICE: 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.





52. 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.





53. Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).










54. 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).





55. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





56. NOTICE: 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.





57. Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).





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





59. Using the Crankshaft Front Oil Seal Installer, the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install the crankshaft front seal into the engine front cover.





60. 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.





61. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





62. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
- Stage 1: Tighten to 120 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.

63. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).





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





65. NOTICE: 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.

66. Apply instant adhesive completely around the gasket groove in the LH 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 LH valve cover and gasket and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).










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





70. 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.





71. Position the RH valve cover and gasket and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).










72. 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).





73. Install 8 new LH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).





74. Install the new LH exhaust manifold gasket and the exhaust manifold. Tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





75. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the nuts.

- Tighten to 25 Nm (18 lb-ft).





76. Install the insert into the LH cylinder head.





77. 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.





78. Install heater outlet tube stud, the ground strap and the nut.
- Tighten the heater outlet tube stud to 25 Nm (18 lb-ft).

- Tighten the nut to 10 Nm (89 lb-in).





79. Position the oil filter adapter and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





80. NOTE: Lubricate the oil filter gasket with clean engine oil.

Install a new oil filter.

- Tighten the oil filter until the gasket makes contact, then use an oil filter strap wrench to tighten the filter an additional 270 degrees.

81. Install the lower radiator hose.





82. NOTICE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the cooling fan.

- Calculate the correct torque wrench setting for the following torque.

- Tighten to 55 Nm (41 lb-ft).





83. Position the cooling fan clutch wiring harness and install the nut.
- To install, tighten to 10 Nm (89 lb-in).





84. Install the Engine Lifting Bracket.





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

86. NOTICE: 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.

87. 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.





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





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





90. NOTICE: 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.

91. 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.





92. 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.





93. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.





94. Tighten the 16 bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.





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

Using the 2 Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.





96. Using the 2 Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear oil slinger.





97. Position the flexplate and install the 6 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).