Steps 32 - 85
32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
Part 1 Of 2:
Part 2 Of 2:
33. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).
34. Loosely install the bolts, then tighten in two stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
35. Install the RH engine mount.
36. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
37. Using the special tools, install the front oil seal.
38. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply sealant to the Woodruff key slot on the crankshaft pulley.
39. Using the special tool, install the crankshaft pulley.
40. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
Tighten the crankshaft pulley bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Rotate an additional 90 degrees (1/4 turn).
41. Position the coolant pump pulley on the water pump and install the bolts.
42. Install the accessory drive belt idler pulley.
43. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply sealant in two places where the engine front cover meets the cylinder head.
44. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
45. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply sealant in two places where the engine front cover meets the cylinder head.
46. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
47. Inspect the O-ring seals. Install new seals if necessary.
48. Install the coolant bypass tube.
49. Install the ground strap on the rear of the RH cylinder head.
1 Install the stud bolt.
2 Install the ground strap.
3 Install the retaining nut.
50. NOTE: Align the gasket locator tabs to slots in cylinder head.
Install new intake manifold gaskets.
51. Install the intake manifold and hand-tighten the bolts at the locations shown.
52. Install the eight ignition coils and tighten the eight bolts.
53. Install the crash bracket and loosely install the bolt and the stud.
54. Install the thermostat.
55. Install the coolant outlet adapter and loosely install the bolts.
56. Tighten the bolts in the sequence shown.
57. Tighten the stud.
58. Tighten the bolts.
59. Install the throttle body and tighten the bolts.
60. Install the throttle return spring.
61. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
62. Connect the EGR tube to the exhaust manifold connector.
63. Position the fuel charging wiring at two locations at the back of the intake manifold.
64. Install the generator.
65. Connect the electrical connector to the idle air control (IAC) valve and the throttle position (TP) sensor.
66. Install the generator mounting bracket.
67. Connect the generator electrical connector, generator cable and harness pin-type retainer.
68. Connect the electrical connector to the EGR vacuum regulator solenoid.
69. Install the generator wiring harness anchor to the LH front stud.
70. Connect the engine coolant temperature (ECT) sensor electrical connector.
71. Connect the crankcase ventilation tube.
72. Install the EGR tube heat shield.
73. Connect the eight fuel injector electrical connectors.
74. Connect the eight ignition coil electrical connectors.
75. Connect the differential pressure feedback EGR system electrical connector.
76. Connect the camshaft position (CMP) sensor electrical connector.
77. Connect the radio interference capacitor electrical connector.
78. Connect the cylinder head temperature (CHT) sensor electrical connector.
79. Connect the ground wire to the right rear fuel rail stud.
80. Install the battery cables and the bolt.
81. Install the RH and LH lifting brackets.
82. Remove the engine from the engine stand.
83. Install the engine/transmission spacer plate.
84. Position the flexplate and install the bolts in the sequence shown.
85. Install the engine.