Part 2

Engine

Assembly

51. Remove the crankshaft pulley bolt.





52. NOTE: 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.





53. Install 3 new gaskets in the front cover.

54. 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 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.





55. NOTE: Fasteners 1 and 13 are stud bolts.

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





56. 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.





57. 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 pulley must be installed and the bolt tightened within 4 minutes of sealant application.

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





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

Using the special tool, install the crankshaft pulley.





59. Install the crankshaft pulley washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 lb-ft).
^ Stage 2: Loosen one full turn (360 degrees).
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten to 90 Nm (66 lb-ft).





60. Install the belt tensioner and the bolt.
^ Tighten to 45 Nm (33 lb-ft).





61. Install the LH idler pulley and the bolt.
^ Tighten to 47 Nm (35 lb-ft).





62. Install the center idler pulley and the bolt.
^ Tighten to 25 Nm (18 lb-ft).





63. Position the oil pan baffle. Install the nuts and tighten in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 lb-in).
^ Stage 2: Tighten 45 degrees.





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





65. 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 lb-in).
- Stage 2: Tighten 45 degrees.





66. Install the new gasket in the LH valve cover in the following sequence:
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.





67. 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 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.





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





69. Install the new gasket in the RH valve cover in the following sequence:
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.

70. 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 prep before applying silicone gasket and sealant.

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





71. Position the RH valve cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





72. Install the radio interference capacitor and the nut.
^ Tighten to 6 Nm (53 lb-in).





73. Install the coolant pump and the bolts.
^ Tighten to 10 Nm (89 lb-in).





74. Connect the coolant pump hose to the cylinder block outlet.





75. Install the bypass tube and the nut and bolt.
^ Tighten to 10 Nm (89 lb-in).





76. Position the coolant tube and connect the hoses.





77. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

Install the special tool in the camshaft as shown in the illustration.
^ Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.





78. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).

Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.
^ Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.





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





80. 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.

81. Lubricate the O-ring seal and install the oil filter.
^ Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.





82. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





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





84. NOTE: Make sure to apply anti-seize lubricant to the threads of the heated oxygen sensor (HO2S) before installation.

Using the special tool, install the LH HO2S.
^ Tighten to 47 Nm (35 lb-ft).





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





86. Position the oil level indicator and tube and install the stud bolt.
^ Tighten to 10 Nm (89 lb-in).





87. Install the engine oil pressure (EOP) switch and, if equipped, the block heater.
^ Tighten the EOP switch to 14 Nm (10 lb-ft).
^ Tighten the block heater to 21 Nm (15 lb-ft).





88. Install the 3 bolts and the A/C compressor bracket.
^ Tighten to 25 Nm (18 lb-ft).





89. Position the generator and install the bolt and 2 nuts.
^ Tighten to 47 Nm (35 lb-ft).





Front wheel drive (FWD) vehicles

90. Install the halfshaft support bracket and the bolts.
^ Tighten to 48 Nm (35 lb-ft).





91. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





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





93. Connect the RH HO2S electrical connector.





All vehicles

94. NOTE: LH shown, RH similar.

Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
Install the 6 coil-on-plugs and the bolts.
^ Tighten to 6 Nm (53 lb-in).





95. NOTE: Install new gaskets.

Install the lower intake manifold and the bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





96. Install the B+ wiring harness on the engine.
^ Attach the 4 wiring harness retainers, and install the nut.
^ Tighten to 6 Nm (53 lb-in).





97. Position the fuel charging wiring harness on the engine.
^ Attach the 2 wiring harness retainers (1 shown) to the engine.





98. Connect the fuel injector electrical connectors.





99. Install the B+ wire and nut on the generator.
^ Tighten to 8 Nm (71 lb-in).





100. Connect the generator electrical connector.





101. Connect the camshaft position sensor (CMP) and EOP switch electrical connectors.
^ Attach the wiring retainers.





102. Connect the LH coil-on-plug electrical connectors.
^ Attach the 2 wiring retainers.





103. Connect the radio interference capacitor electrical connector.
^ Attach the wiring retainers.





104. Connect the RH coil-on-plug electrical connectors.
^ Attach the 2 wiring harness retainers.





105. Connect the engine coolant temperature (ECT) sensor electrical connector.





106. NOTE: Install new gaskets.

Install the upper intake manifold and the bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





107. Connect the throttle body (TB) coolant hose.





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





109. Install the PCV tube.





110. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
^ Attach the wiring retainer.





111. Position the engine control wiring harness and install the nuts.
^ Tighten to 6 Nm (53 lb-in).





112. Connect the EGR vacuum regulator electrical connector.





113. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.





114. Position the catalyst monitor sensor electrical connector bracket. Install the nut and attach the wiring retainer.
^ Tighten to 10 Nm (89 lb-in).





115. Attach the engine control sensor wiring connectors to the upper intake manifold.





116. Using the special tools, remove the engine from the engine stand.