Part 2

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 4 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 4 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 303-009 or suitable strap wrench to hold the pulley.

Tighten the crankshaft pulley bolt in 4 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. 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 and pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).





65. Position the oil pump screen and pickup tube, and install the 3 bolts.
1. Tighten to 25 Nm (18 ft. lbs.).
2. Tighten to 10 Nm (89 inch lbs.).





66. Install the new oil filter adapter gasket, oil filter adapter and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.





67. 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 4 bolts and tighten to 25 Nm (18 ft. lbs.).





68. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





69. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





70. NOTE: If not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply sealant in 2 places where the engine front cover meets the cylinder head.





71. Install the new LH gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





72. NOTE: If not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply sealant in 2 places where the engine front cover meet the cylinder head.





73. Install the new RH gasket into the valve cover and position on the cylinder head. Tighten the 11 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





74. Install the knock sensor (KS) and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





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





76. Install the coolant bypass tube.





77. Install the ground strap on the rear of the RH cylinder head.
1. Install the stud bolt and tighten to 25 Nm (18 ft. lbs.).
2. Install the ground strap.
3. Install the retaining nut and tighten to 10 Nm (89 inch lbs.).





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

Install new intake manifold gaskets.





79. Install the intake manifold and hand-tighten the 8 bolts at the locations shown.





80. Install the 8 ignition coils and tighten the 8 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





81. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud.





82. Install the thermostat.





83. Install the coolant outlet adapter and loosely install the 2 bolts.





84. Tighten the 9 bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





85. Tighten the stud.
^ Tighten to 25 Nm (18 ft. lbs.).





86. Tighten the 2 coolant outlet adapter bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





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





88. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
^ Tighten to 40 Nm (30 ft. lbs.).





89. Connect the EGR tube to the exhaust manifold.
^ Tighten to 40 Nm (30 ft. lbs.).





90. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
91. Install the generator and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





92. Install the generator mounting bracket and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





93. Connect the generator electrical connector.





94. 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.





95. Install the generator wiring harness anchor to the LH front stud.





96. Connect the crankcase ventilation tube.





97. Install the intake manifold shield and 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).





98. Connect the 8 fuel injector electrical connectors.





99. Connect the 8 ignition coil electrical connectors.





100. Connect the camshaft position (CMP) sensor electrical connector.





101. Connect the radio interference capacitor electrical connector.





102. Connect the KS electrical connector and install the harness retainer to the intake manifold.





103. Connect the cylinder head temperature (CHT) sensor electrical connector.





104. Connect the ground wire to the right rear fuel rail stud.





105. Install the battery cables and the bolt.

106. NOTE: RH shown, LH similar.

Install the RH and LH lighting brackets.





107. Remove the engine from the engine stand.





108. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker
must be applied to the rear crankshaft seal retainer mating surface on the engine block.

Apply a bead of gasket maker to the rear crankshaft seal retainer mating surface on the engine block.





109. Install the rear oil seal retainer and loosely install the 6 bolts.





110. Tighten the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





111. NOTE: If the oil pan is not secured within 4 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 4 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.





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





113. Position the new oil pan gasket, the oil pan and the loosely install the 16 bolts.





114. Tighten the 16 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Rotate an additional 60 degrees.





115. Using the special tools, install the crankshaft rear oil seal.





116. Using the special tools, install the crankshaft oil slinger.





117. Install the engine/transmission spacer plate.





118. Position the flexplate and install the 6 bolts in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs.).