Part 3
EngineAssembly (Steps 69-103)
69. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
70. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
71. Using the special tools, install a new crankshaft front seal.
72. NOTE: If the engine 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.
73. Using the special tool, install the crankshaft pulley.
74. 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).
75. Position the RH engine support insulator and install the 4 bolts.
^ Tighten to 80 Nm (59 ft. lbs).
76. Position the LH engine support insulator and install the 4 bolts.
^ Tighten to 80 Nm (59 ft. lbs).
77. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 ft. lbs).
78. Install the engine control sensor wiring harness. Connect all of the harness routing clips and connector retainers.
79. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
80. Connect the CMP electrical connector.
81. Connect the RH radio frequency interference capacitor electrical connector.
82. Connect the knock sensor (KS) electrical connector, if equipped.
83. Connect the CKP sensor electrical connector.
84. Connect the engine oil pressure (EOP) switch electrical connector.
85. Install the special tool.
86. Install the special tool.
87. Install the special tool and remove the engine from the work stand.
88. 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 clean the sealing surfaces.
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.
89. NOTE: If the engine 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 a 4 mm (0.16 inch) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
90. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
91. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs).
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 a new crankshaft rear oil slinger.
94. 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 clean sealing surfaces.
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.
95. NOTE: If the engine 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 at the rear oil seal retainer-to-cylinder block sealing surface.
96. NOTE: If the engine 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 at the engine front cover-to-cylinder block sealing surface.
97. Install a new oil pan gasket and the oil pan and loosely install the bolts.
98. Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 2 Nm (18 inch lbs).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs).
^ Stage 3: Tighten an additional 60 degrees.
99. Install the oil drain plug.
100. Lower the engine onto wooden blocks.
101. Install the special tool and raise the engine.
102. 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).
103. Install the engine.