Part 2

51. NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.

52. Remove the special tool.

53. Install all eight spark plugs.

54. Install the crankshaft sensor ring.

55. NOTE: RH timing chain removed for clarity.

NOTE: If the engine front cover is 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 follow this procedure can cause future oil leakage.

Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.

56. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger tight.

57. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).

58. NOTE: RH shown; LH similar.

Install the RH and LH engine mounts.

59. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.

60. Using the special tools, install the front oil seal.

61. 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.

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

63. NOTE: Use special tool 303009 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).

64. NOTE: If the rear crankshaft seal retaining plate is 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 follow this procedure can cause future oil leakage.

NOTE: The silicone must be applied on the groove along the retainer plate.

Apply 4 mm (0.16 inch) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.

65. Install the rear oil seal retainer and loosely install the six bolts.

66. Tighten the bolts in the sequence shown.

67. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring seal. Lubricate the O-ring seal with clean engine oil.

Install the oil pump screen cover and tube spacer.

68. Position the oil pump screen cover and tube, and install the bolts.

69. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas 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 the sealant at the rear oil seal retainer-to-cylinder block sealing surface.

70. Apply sealant at the front cover-to-cylinder block sealing surface.

71. Position the oil pan gasket, the oil pan and the bolts on the engine.

72. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Rotate an additional 60 degrees.

73. Install the oil filter adapter.

74. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the coolant pump.
1. Lubricate the new O-ring seal using engine coolant.
2. Position the coolant pump into the engine block.
3. Install the bolts.

75. Position the coolant pump pulley on the coolant pump and install the bolts.

76. Position the belt idler pulley and install the bolt.

77. 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.

78. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.

79. 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 meet the cylinder head.

80. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.

81. Install the knock sensor (KS) and the bolts.

82. Inspect the O-rings seals. Install new seals if necessary.

83. Install the coolant bypass tube.

84. 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.

85. NOTE: Align the gasket locator tabs to slots in cylinder head.

Install new intake manifold gaskets.

86. Install the intake manifold and hand-tighten the bolts at the locations shown.

87. Install the eight ignition coils and tighten the eight bolts.

88. Install the crash bracket and loosely install the bolt and the stud.

89. Install the thermostat.

90. Install the coolant outlet adapter and loosely install the bolts.

91. Tighten the bolts in the sequence shown.

92. Tighten the stud.

93. Tighten the bolts.

94. Install the throttle body and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).

95. Connect the throttle control and throttle positioning sensor electrical connector.

96. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.

97. Connect the EGR tube to the exhaust manifold connector.
98. Position the fuel charging wiring at two locations at the back of the intake manifold.

99. Install the generator.

100. Install the generator mounting bracket.

101. Connect the generator electrical connector.

102. Position the vacuum harness and connect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.