Part 3
Engine - 5.4LAssembly (Steps 69-103)
69. 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).
70. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the oil level indicator tube and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
71. Install the oil level indicator and tube support bracket nut.
^ Tighten to 25 Nm (18 ft. lbs).
72. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 ft. lbs).
73. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
74. Connect the CKP sensor electrical connector.
75. Connect the engine oil pressure (EOP) switch electrical connector.
76. Connect the knock sensor (KS) electrical connector.
77. Connect the RH radio frequency interference capacitor electrical connector.
78. Connect the CMP sensor electrical connector.
79. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
80. NOTE: LH shown, RH similar.
Install the cylinder block drain plugs.
^ Tighten to 20 Nm (15 ft. lbs).
81. Position the oil filters adapter gasket and the oil filter adapter. Install the nuts and bolts.
^ Tighten the front bolts to 25 Nm (18 ft. lbs).
^ Tighten the rear nut to 48 Nm (35 ft. lbs).
82. NOTE: RH shown, LH similar.
Position the RH and LH engine support insulators and install the 6 bolts.
^ Tighten to 63 Nm (46 ft. lbs).
83. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
84. Install the pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs).
85. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.
Position the oil pump screen and pickup tube and install the bolts.
1 Tighten to 25 Nm (18 ft. lbs).
2 Tighten to 10 Nm (89 inch lbs).
86. Install the special tool.
87. Install the special tool.
88. Install the special tool and remove the engine from the work 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 crankshaft 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 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
91. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
92. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs).
93. 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.
94. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with 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.
95. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with 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.
96. Install the oil pan gasket and the oil pan and loosely install the bolts.
97. Tighten the bolts in 3 stages, 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 60 degrees.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
100. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install a new crankshaft rear seal.
101. Using the special tools, install a new crankshaft rear oil slinger.
102. Install the flexplate and the 8 bolts. Tighten the 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.