Steps 61-94

61. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.








62. 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.).








63. Install the belt idler pulley and tighten the bolt.





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

Position the oil pump screen and pickup tube.
1 Install and tighten the spacer.
2 Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer.
3 Install and tighten the bolts.

65. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.





66. 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 at the rear oil seal retainer-to-cylinder block sealing surface.





67. 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 at the engine front cover-to-cylinder block sealing surface.





68. NOTE: Be sure to tighten the bolts in three stages.

Install the oil pan. Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.

69. Install the oil drain plug.





70. CAUTION: Do not rotate the coolant pump housing once the water 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, and install the O-ring seal onto the coolant pump.
2 Position the coolant pump into the cylinder block.
3 Install the coolant pump retaining bolts.





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





72. Using the special tool, install the crankshaft front seal into the engine front cover.





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





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





75. 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: Tighten an additional 90 degrees.





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





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 silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
78. Position the valve covers.





79. Tighten the bolts in the sequence shown.
80. Install the engine control sensor wiring harness. Connect all of the harness routing clips and connector retainers.





81. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





82. Disconnect the Camshaft Position (CMP) electrical connector.





83. Disconnect the RH radio frequency interference capacitor electrical connector.





84. Disconnect the Knock Sensor (KS) electrical connector.





85. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





86. Disconnect the oil pressure switch electrical connector.





87. Attach the special tool.
88. Remove the engine from the engine stand.

89. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.





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





91. Install the retainer plate. Tighten the bolts in two stages.
^ Stage 1: Tighten the retainer plate bolts to 10 Nm (89 inch lbs.), in the sequence shown.
^ Stage 2: Tighten the oil pan bolts to 20 Nm (15 ft. lbs.), then tighten an additional 90 degrees.





92. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the special tools, install a new crankshaft rear seal.





93. Using the special tools, install the crankshaft rear oil slinger.





94. Install the flexplate.