Part 4

Engine















Engine - Upper End















Engine - Lower End

















NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Engine System - General Information Specifications.


91. NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.

Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.





92. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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





93. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.





94. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.





95. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 140 Nm (103 lb-ft).

- Stage 2: Loosen 360 degrees.

- Stage 3: Tighten to 100 Nm (74 lb-ft).

- Stage 4: Tighten an additional 90 degrees.





96. Install the generator, the bolt and the nut.
- Tighten to 48 Nm (35 lb-ft).





97. Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).





98. Attach the 3 wiring harness retainers (2 shown) from the engine front cover and stud bolts.





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

Using a new O-ring seal, install the coolant pump and the 4 bolts.

- Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.





100. Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





101. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.





102. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).





103. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.





104. Position the LH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).





105. Install the oil level indicator.

106. Install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Connect the LH intake and exhaust CMP sensor electrical connectors.





107. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.





108. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).





109. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.





110. Position the RH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).





111. Install the RH intake and exhaust CMP sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Connect the RH intake and exhaust CMP sensor electrical connectors.





112. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.





113. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown, LH similar.

Install the 8 ignition coils and 8 bolts.

- Tighten to 6 Nm (53 lb-in).





114. NOTE: RH shown, LH similar.

Attach the 9 wiring harness retainers to the RH valve cover and the 10 wiring harness retainers to the LH valve cover.





115. NOTE: RH shown, LH similar.

Connect the 8 ignition coil electrical connectors.





116. NOTE: RH shown, LH similar.

Connect the 4 VCT variable force solenoid electrical connectors.





117. Connect the CHT sensor and the CKP sensor electrical connectors.





118. Connect the 2 KS electrical connectors.





119. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.





120. Connect the oil level sensor electrical connector and the 2 wiring harness retainers.





121. Install the Engine Lifting Bracket





122. Using the Heavy Duty Floor Crane, remove the engine from the work stand.

123. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





124. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





125. Install the crankshaft sensor ring.





126. Install the engine separator plate, the flywheel or flexplate and the 8 bolts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 60 degrees.





127. NOTE: If installing the original pressure plate, align it using the index marks made during removal.

NOTE: Always install new pressure plate bolts.

If equipped, use suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 6 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured.

- Tighten the pressure plate bolts in 2 stages in a star pattern.
- Stage 1: Tighten to 47 Nm (35 lb-ft).

- Stage 2: Tighten an additional 60 degrees.