Part 2
Cylinder HeadInstallation (Steps 35-69)
35. Tighten the engine front cover fasteners in sequence in 2 stages.
^ Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 ft. lbs).
^ Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 ft. lbs).
36. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten an additional 60 degrees.
37. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
38. NOTE: If the front cover is 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. 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.
NOTE: LH shown, RH similar.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
39. Position the valve covers.
40. Tighten the fasteners in the sequence shown.
41. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs).
42. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
43. Using the special tools, install a new crankshaft front seal.
44. NOTE: If the front cover is 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. 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
45. Using the special tool, install the crankshaft pulley.
46. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 ft. lbs).
47. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
48. NOTE: The front lower hole in the power steering pump is not used.
Position the power steering pump and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
49. Position the oil level indicator tube.
50. Install the bolt attaching the oil level indicator tube to the LH cylinder head.
^ Tighten to 10 Nm (89 inch lbs).
51. Install the oil level indicator and tube support bracket nut.
^ Tighten to 25 Nm (18 ft. lbs).
52. Position the crankcase vent tube and connect the quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
53. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 ft. lbs).
54. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
55. Connect the crankshaft position (CKP) sensor electrical connector.
56. Connect the engine oil pressure (EOP) switch electrical connector.
57. Connect the knock sensor (KS) electrical connector.
58. Connect the RH radio frequency interference capacitor electrical connector.
59. Connect the camshaft position (CMP) sensor electrical connector.
60. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
61. NOTE: LH shown, RH similar.
Install the cylinder block drain plugs.
^ Tighten to 24 Nm (18 ft. lbs).
62. Position the RH engine support insulator and install the 3 bolts.
^ Tighten to 63 Nm (46 ft. lbs).
63. Install the special tool.
64. Install the special tool.
65. Install the special tool and remove the engine from the work stand.
66. Lower the engine onto wooden blocks.
67. Install the special tool and raise the engine.
68. Position the flexplate and tighten the 8 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten to 80 Nm (59 ft. lbs).
69. Install the engine.