Part 2

Cylinder Heads





37. Lubricate the front oil seal and the engine front cover with clean engine oil.





38. Using the special tool, install the front oil seal.





39. NOTE: If not secured within four minutes, the 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 do this procedure can result in future oil leakage.

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





40. Using the special tool, install the crankshaft pulley.





41. NOTE: Use a suitable strap wrench to hold the pulley while tightening the bolt.

Install the crankshaft pulley and tighten the bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tight an additional 90 degrees.





42. Install the coolant pump pulley.





43. Install the RH exhaust manifold.
^ Install a new RH exhaust manifold gasket.
^ Install the RH exhaust manifold.
^ Tighten the nuts in the sequence shown.





44. Inspect O-ring seals and install O-ring seals as necessary.





45. Install the coolant bypass tube.
^ Install the nut and tighten to 25 Nm (18 ft. lbs.).





46. 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.





47. Position the bracket and install the nut.





48. NOTE: Lubricate the O-ring with clean engine oil.

Install the oil level indicator tube.
^ Install a new O-ring on the oil level indictor tube.





49. Install the LH exhaust manifold.
^ Install a new LH exhaust manifold gasket.
^ Install the LH exhaust manifold.
^ Tighten the nuts in the sequence shown.





50. Install the wiring harness and connect the retainers.





51. NOTE: LH shown, RH similar

Install and connect the radio capacitor.





52. Connect the Camshaft Position (CMP) sensors and the engine wiring harness retainers.





53. Connect the oil pressure sensor electrical connector.





54. Connect the knock sensor.





55. Install the eight ignition coils.





56. Connect the eight ignition coils.





57. Install the RH ignition coil cover.





58. Install the LH coil cover.





59. Install the lower intake manifold gaskets.
60. Connect the fuel charging wiring harness to the rear of the lower intake manifold and install the manifold.





61. Install the intake manifold fasteners and tighten in the sequence shown.





62. Connect the eight fuel injectors.





63. Position the fuel charging wiring harness and connect the fuel injection supply manifold in three places.





64. Connect the electrical connector and the vacuum hose to the fuel pressure sensor.





65. Install the generator and bolts.





66. Install the crossover tube.
^ Inspect and install new O-ring seals if necessary.





67. Install the generator support bracket and the four bolts.





68. Connect the electrical connector, generator cable and the harness pin-type retainer.





69. Connect the Engine Coolant Temperature (ECT) sensor electrical connectors.





70. Install a new upper intake manifold gasket.





71. Install the upper intake manifold and tighten the bolts in the sequence shown.





72. Connect the vacuum hoses and the Positive Crankcase Ventilation (PCV) heater hoses.





73. Connect the PCV tube.





74. Connect the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor electrical connectors.





75. Connect the Exhaust Gas Recirculation (EGR) system module tube to the EGR system module.





76. Connect the EGR system module tube to the exhaust manifold connector.





77. Install the bracket and the bolt.





78. Install the RH engine mount and the bolts.





79. Install the special tools.





80. Remove the engine from the stand.





81. Install the engine/transmission spacer plate.





82. Install the flexplate.
83. Install the engine.