Installation

Oil Pan

Special Tool(s) (Part 2):

Material:

CAUTION: 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.

All vehicles

1. NOTE: The oil pan and bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 5 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

Apply a 3 mm (0.11 inch) bead of silicone gasket sealant to the sealing surface of the oil pan.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket sealant to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

2. Install the oil pan and the 16 bolts.
^ Tighten the bolts in the sequence shown to 3 Nm (27 inch lbs).
^ Loosen the bolts 180 degrees.

3. Align the oil pan to the cylinder block and the A/C compressor.
^ Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

4. Tighten the oil pan bolts in the sequence shown.
^ Tighten the large bolts (1-14) to 20 Nm (15 ft. lbs).
^ Tighten the small bolts (15 and 16) to 10 Nm (89 inch lbs).

5. Install the A/C compressor mounting stud and nut.
^ Tighten the stud to 9 Nm (80 inch lbs) and the nut to 25 Nm (18 ft. lbs).

6. Install the special tools.

7. NOTE: If the engine front cover, engine mount bracket and bolts 7, 8, 17, 18, 19, 20, 23, 24 and 25 are not installed and tightened within 10 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply a 3.0 mm (0.11 inch) bead of silicone gasket and sealant to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket and sealant to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover.

8. Install the engine front cover and bolts 7, 8, 17, 18, 19 and 20.
^ Tighten in sequence to 10 Nm (89 inch lbs).

9. Install the engine mount bracket and the 3 bolts.
^ Tighten in the sequence shown to 15 Nm (11 ft. lbs).

10. Tighten the bolts in this sequence.
^ Tighten bolts 7, 8, 17, 18, 19 and 20 to 24 Nm (18 ft. lbs).
^ Tighten bolts 23, 24 and 25 to 75 Nm (55 ft. lbs).

11. Remove the special tools (alignment pins).

12. NOTE: The remainder of the engine front cover bolts (1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22) must be installed and tightened within 60 minutes of the initial sealant application.

Install bolts 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22 and tighten in the sequence shown in 2 stages:
^ Stage 1: Tighten to 10 Nm (89 inch lbs).
^ Stage 2: Tighten to 24 Nm (18 ft. lbs).

13. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 ft. lbs).

14. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

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

15. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the special tools, install the crankshaft pulley.

16. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees.

17. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, variable camshaft timing (VCT) seal installation similar.

Using the special tools, install new VCT solenoid and/or spark plug tube seals.

18. 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

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

19. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).

20. 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

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

21. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).

22. NOTE: LH shown, RH similar.

Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 inch lbs).

23. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 ft. lbs) plus an additional 180 degrees.

24. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 ft. lbs).

Front wheel drive (FWD) vehicles
25. Using a new gasket, install the RH catalytic converter and 4 new nuts.
^ Tighten to 40 Nm (30 ft. lbs).

All vehicles
26. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
^ Tighten to 40 Nm (30 ft. lbs).

27. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs).

28. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).

29. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
30. Connect the 3 LH coil-on-plug electrical connectors.

31. Connect the LH camshaft VCT solenoid electrical connector.

32. Connect the LH catalyst monitor sensor electrical connector.

33. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
34. Connect the heated positive crankcase ventilation (PCV) valve electrical connector.

35. Connect the 3 RH coil-on-plug electrical connectors.

36. Connect the RH VCT solenoid electrical connector.

FWD vehicles
37. Connect the RH catalyst monitor sensor electrical connector.

All vehicles
38. Connect the power steering pressure (PSP) switch electrical connector.

39. Using new gaskets, install the upper intake manifold and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).

40. Install the upper intake manifold support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs).

41. Install the upper intake manifold support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs).

42. Attach the wiring harness retainers to the upper intake manifold.

43. Connect the throttle body electrical connector.

44. Connect the PCV hose to the PCV valve.

45. Connect the PCV fitting electrical connector.

46. If equipped, position the engine block heater harness on the engine and attach all of the harness retainers.
^ Connect the engine block heater electrical connector and install the heat shield.

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

48. Install the crankshaft sensor ring.

49. Install the flexplate and the 8 bolts.
^ Tighten to 80 Nm (59 ft. lbs).

50. Install the engine in the vehicle.