Steps 36-71

36. Install the crankshaft sensor ring on the crankshaft.





37. NOTE: If the front cover is not secured within four 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 a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.





38. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.








39. Tighten the engine front cover fasteners in sequence in two stages.
Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 ft. lbs.).
Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 ft. lbs.).








40. 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 60 degrees.





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





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





43. Using the special tools, install the crankshaft front seal.





44. NOTE: If not secured within four 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





45. Use the special tool to install the crankshaft pulley.





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

Tighten the new crankshaft 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: Tighten an additional 90 degrees.





47. Position the water pump pulley on the water pump and install the bolts.





48. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.





49. NOTE: If not secured within four 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 silicone gasket and sealant in two places where the engine front cover meets the cylinder head.





50. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.





51. Tighten the bolts in the sequence shown.





52. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.





53. NOTE: If not secured within four 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 silicone gasket and sealant in two places where the engine front cover meets the cylinder head.





54. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.





55. Tighten the bolts in the sequence shown.





56. Install the crankcase ventilation tube on the LH valve cover.





57. Install the Positive Crankcase Ventilation (PCV) valve and hose in the RH valve cover.





58. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors.
59. Position the engine control sensor wiring harness and connect the wiring harness retainers onto the valve cover studs.





60. Install the bracket.





61. Connect the Crankshaft Position (CKP) sensor electrical connector.





62. Connect the oil pressure switch electrical connector.





63. Connect the KS electrical connector.





64. Connect the RH radio ignition interference capacitor electrical connector.





65. Connect the CMP electrical connector.





66. Connect the LH radio ignition interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





67. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
68. Install the RH engine mount.
^ Tighten the bolts to 63 Nm (46 ft. lbs.).





69. Install the special tool and remove the engine from the work stand.





70. Install the flexplate and the bolts in the sequence shown.
71. Install the engine.