Part 2

Assembly Continued





36. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
^ Tighten the 8 mm bolts to 10 Nm (1.0 kgf-m, 89 inch lbs.).
^ Tighten the 13 mm bolts to 48 Nm (4.9 kgf-m, 35 ft. lbs.).





Note:
^ Remove the through-bolt from the special tool.

Note:
^ Lubricate the oil seal with clean engine oil.

37. Using the special tool, install a new crankshaft front oil seal.

Note:
^ Do not reuse the crankshaft damper bolt.

Note:
^ Apply clean engine oil on the seal area before installing.

38. Install the crankshaft pulley and hand-tighten the bolt.





Caution:
^ Only hand-tighten the bolt or damage to the front cover can occur.

Note:
^ This step will correctly align the crankshaft pulley to the crankshaft.

39. Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.
^ Rotate the pulley as necessary to align the bolt holes.





Caution:
^ Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.

40. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages:
^ Stage 1: Tighten to 100 Nm (10.2 kgf-m, 74 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).





41. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





42. Remove the special tool.





43. Remove the special tool.

Note:
^ Only turn the engine in the normal direction of rotation.

44. Turn the engine two complete revolutions.

Note:
^ Only turn the engine in the normal direction of rotation.

45. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).





46. Install the special tool.





Caution:
^ Only hand-tighten the bolt or damage to the front cover can occur.

47. Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, correct the engine timing.





48. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.





Note:
^ Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment jig supplied with the new part.

49. Install a new CKP sensor.
^ Do not tighten the bolts at this time.





50. Adjust the CKP sensor alignment jig and tighten the bolts.





51. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





52. Install the engine plug bolt.

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.

53. Clean the valve cover gasket surface with metal surface cleaner.





54. Apply silicone gasket and sealant to the locations shown.





Note:
^ The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

55. Install the valve cover.
^ Tighten the bolts in the sequence shown.





56. Install a new cylinder head temperature (CHT) sensor and the spark plugs.





Note:
^ Apply dielectric compound to the inside of the coil-on-plug boots.

57. Install the coil-on-plugs and the crankcase vent tube.





58. If equipped, install the block heater.





Note:
^ The knock sensor (KS) must not touch the crankcase vent oil separator.

59. Install the crankcase vent oil separator and the KS.





60. Install the coolant hoses.





61. Install the coolant hose.





62. Install the coolant hose.





63. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.





64. Attach the wiring harness retainer.





65. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





66. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.





67. Attach the wiring harness retainer.





Caution:
^ Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

68. Install new fuel injector O-rings.
^ Separate the fuel injectors from the fuel rail.
^ Remove and discard the fuel injector O-rings.
^ Install new O-rings and lubricate with clean engine oil.
^ Install the fuel injectors onto the fuel rail.





69. Position the fuel rail spacers.





70. Install the fuel rail with the fuel injectors.





71. Connect the four fuel injector electrical connectors. Attach the two wiring harness retainers.





72. Install the EGR tube.





73. Position the intake manifold and connect the positive crankcase ventilation hose.





Note:
^ Inspect and install new intake manifold gaskets, if necessary.

74. Install the intake manifold gaskets and intake manifold.





75. Connect the throttle position (TP) sensor electrical connector.





76. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.





77. Connect the swirl control valve electrical connector.





78. Connect the idle air control (IAC) motor electrical connector.





79. Connect the temperature manifold absolute pressure (TMAP) electrical connector.





80. Connect the KS and attach the two wiring harness retainers.





81. Attach the two wiring harness retainers.





82. If removed, install the capacitor and bolt.





Note:
^ Clean the gasket mating surfaces with metal surface cleaner,

83. Install the oil filter adapter with a new gasket.





84. Connect the oil pressure sensor electrical connector.

Note:
^ Install a new O-ring on the oil level indicator tube and lubricate with clean engine oil prior to installing.





85. Install the oil level indicator and bolts.





Note:
^ Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.

86. Install the thermostat housing and bolts.





87. Connect the oil cooler hoses.





88. Attach the two wiring harness retainers.





89. Install the engine vacuum tube.
^ Connect the engine vacuum tube.
^ Attach the two engine vacuum tube retainers.





Note:
^ Clean the coolant pump mating surface with metal surface cleaner.

Note:
^ Lubricate the coolant pump O-ring with clean engine coolant.

90. Install the coolant pump.





91. Install the coolant pump pulley.





92. If equipped, install the accessory drive belt idler pulley.





93. Install the accessory drive belt idler pulley.





94. Install the accessory drive belt tensioner.





95. Install the generator.





96. Install the generator cover.





97. Connect the generator electrical connections and install the nut.





98. Install the generator cooling duct.





99. Connect the CKP sensor electrical connector.
100. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.





101. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten to 50 Nm (5.1 kgf-m, 37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (8.2 kgf-m, 59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (11.4 kgf-m, 83 ft. lbs.).





102. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten to 50 Nm (5.1 kgf-m, 37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (8.2 kgf-m, 59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (11.4 kgf-m, 83 ft. lbs.).





103. Install the starter motor isolator.





104. Lubricate the transaxle input shaft pilot bearing with front axle grease.





105. Using the special tool, position the clutch disc on the flywheel.

Note:
^ If reusing the clutch pressure plate and flywheel, align the marks made during removal.





106. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.