Steps 41-88
Cylinder Head
Installation
41. Loosely install the 4 bolts, then tighten in 2 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
42. NOTE: RH shown, LH similar.
Install the RH and LH engine mounts and the bolts.
- Tighten to 70 Nm (52 lb-ft).
43. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
44. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
45. NOTICE: If not secured within 4 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 sealant to the Woodruff key slot on the crankshaft pulley.
46. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
47. NOTE: Use a Strap Wrench to hold the pulley.
Tighten the crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Rotate an additional 90 degrees (one-quarter turn).
48. Position the coolant pump pulley on the coolant pump and install the bolts.
- Tighten to 25 Nm (18 lb-ft).
49. Install the accessory drive belt idler pulley and bolt.
- Tighten to 25 Nm (18 lb-ft).
50. NOTICE: If not secured within 4 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 sealant in 2 places where the engine front cover meets the cylinder head.
51. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
52. NOTICE: If not secured within 4 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 sealant in 2 places where the engine front cover meets the cylinder head.
53. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
54. Inspect the O-ring seals. Install new seals if necessary.
55. Install the coolant bypass tube.
56. Install the ground strap on the rear of the RH cylinder head.
1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).
2. Install the ground strap.
3. Install the retaining nut and tighten to 10 Nm (89 lb-in).
57. Install the insert into the LH cylinder head.
58. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Align the gasket locator tabs to slots in cylinder head.
Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts at the locations shown.
59. Install the 8 ignition coils and tighten the 8 bolts (4 shown).
- Tighten to 6 Nm (53 lb-in).
60. Install the intake manifold bracket and loosely install the bolt and the stud bolt.
61. Install the thermostat.
62. Install the coolant outlet adapter and loosely install the 2 bolts.
63. Tighten the bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
64. Tighten the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
65. Tighten the bolts.
- Tighten to 25 Nm (18 lb-ft).
66. Connect the EGR tube to the EGR valve.
- Tighten to 43 Nm (32 lb-ft).
67. Connect the EGR tube-to-exhaust manifold connector.
- Tighten to 43 Nm (32 lb-ft).
68. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
69. Install the generator and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
70. Connect the throttle control and the Throttle Position (TP) sensor electrical connector.
71. Install the generator mounting bracket and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
72. Attach the wire harness retainer and connect the generator electrical connector.
73. Connect the electrical connector to the EGR vacuum regulator solenoid.
74. Connect the crankcase ventilation tube and if equipped, the heated PCV valve electrical connector.
75. Install the intake manifold shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
76. Connect the 8 fuel injector electrical connectors (4 shown).
77. Connect the 8 ignition coil electrical connectors.
78. Connect the Camshaft Position (CMP) sensor electrical connector.
79. Connect the radio interference capacitor electrical connector.
80. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
81. Install the battery cables and the bolt.
82. Install the Engine Lifting Bracket to the RH cylinder head.
83. Install the Engine Lifting Bracket to the LH cylinder head.
84. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.
85. Install the engine/transmission spacer plate.
86. Position the flexplate and install the bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
87. Install the engine. For additional information, refer to Engine Engine - Installation in the Installation portion.
88. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury. Procedures
If equipped with a fire suppression system, repower the system.