Part 2
Cylinder HeadInstallation (Steps 36-69)
36. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
37. Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.)
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.)
38. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
39. Install the 4 front oil pan bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.)
^ Stage 2: Tighten an additional 60 degrees.
40. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
41. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.)
42. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
43. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
44. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.)
45. Install the oil level indicator tube and the bolt.
^ Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 inch lbs.)
46. Position the RH engine support insulator and install the 3 bolts.
^ Tighten to 63 Nm (46 ft. lbs.)
47. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
48. Using the special tools, install a new crankshaft front seal into the engine front cover.
49. 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
50. Using the special tool, install the crankshaft pulley.
51. Tighten the new crankshaft pulley bolt in 4 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.
52. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.)
53. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.)
54. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Position the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.)
55. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.)
56. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
^ Tighten to 25 Nm (18 ft. lbs.)
57. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
58. NOTE: LH shown, RH similar.
Install the 8 ignition coils and the 8 bolts.
^ Tighten to 6 Nm (53 inch lbs.)
59. Install the LH radio ignition interference capacitor and the nut.
^ Tighten to 25 Nm (18 ft. lbs.)
60. Connect the cylinder head temperature (CHT) sensor electrical connector.
61. Connect the 4 RH ignition coil electrical connectors.
62. Connect the electrical connector retainer to the coolant tube.
63. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
64. NOTE: RH shown, LH similar.
Connect the RH and LH VCT solenoid electrical connectors.
65. Install the RH radio ignition interference capacitor and the stud bolt.
^ Tighten to 25 Nm (18 ft. lbs.)
66. NOTE: RH shown, LH similar.
Connect the RH and LH CMP sensor electrical connectors.
67. Using a suitable floor crane, remove the engine from the engine stand.
68. Install the flexplate and the 8 bolts in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs.)
69. Install the engine.