Part 2
Engine
Engine - Upper End
Engine - Lower End
61. NOTICE: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
Position the coolant pump and install the 4 bolts loosely.
62. Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).
63. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
64. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
65. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
66. Install the LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
67. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
68. NOTE: If 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. 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 RH cylinder head.
69. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid may be damaged.
Position the RH valve cover and gasket on the cylinder head and tighten the 9 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
70. NOTE: If 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. 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 LH cylinder head.
71. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid may be damaged.
Position the LH valve cover and gasket on the cylinder head and tighten the 10 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
72. Inspect the RH exhaust manifold for flatness. For additional information, refer to Engine.
73. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
74. Position new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
75. Position the RH heat shield and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
76. Position the RH engine support insulator bracket and install the 4 bolts.
- Tighten to 72 Nm (53 lb-ft).
77. Position the oil level indicator tube and install 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 lb-in).
78. Inspect the LH exhaust manifold for flatness. For additional information, refer to Engine.
79. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
80. Position new gaskets, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
81. Position the LH exhaust manifold heat shield and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
82. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
Clean the oil filter adapter sealing surfaces using silicone gasket remover, metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
83. NOTICE: 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.
NOTE: Clean and inspect the mating surfaces and install new gaskets.
Position the oil filter adapter and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
84. NOTE: Lubricate the oil filter gasket with clean engine oil.
Install a new oil filter.
- Tighten the oil filter until the gasket makes contact, then use an oil filter strap wrench to tighten the filter an additional 270 degrees.
85. Position the LH engine support insulator bracket and install the 4 bolts.
- Tighten to 72 Nm (53 lb-ft).
86. NOTE: LH shown, RH similar.
Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
87. Connect the PCV hose to the LH valve cover.
88. Connect the breather tube to the RH valve cover.
89. NOTE: Install new O-ring seals and lubricate the O-ring seals with clean engine coolant.
Position the heater supply tube and the hoses as an assembly and install the stud bolt.
- Tighten to 10 Nm (89 lb-in).
90. Position the Knock Sensor (KS) and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
91. Position the ground strap and install the nut.
92. Attach the KS electrical connector retainer.
93. Position the wiring harness and attach the electrical connector and wiring harness retainers to the heater supply tube.
94. Connect the KS electrical connector.
95. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
96. Attach the wiring harness retainers to the RH valve cover studs.
97. NOTE: RH shown, LH similar.
Connect the 4 RH and 4 LH ignition coil electrical connectors.
98. Attach the wiring harness retainers to the LH valve cover studs.
99. Position the LH radio interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).
100. Position the cooling fan wiring harness and install the nut.
- Tighten to 25 Nm (18 lb-ft).
101. Connect the LH Camshaft Position (CMP) sensor and attach the wiring harness retainers.
102. Connect the Engine Oil Pressure (EOP) sensor electrical connector.
103. Position the RH radio interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).
104. Attach the wiring harness retainers.
105. NOTE: RH shown, LH similar.
Connect the RH and LH Variable Camshaft Timing (VCT) solenoid electrical connectors.
106. Connect the RH CMP sensor electrical connector.
107. Connect the CKP sensor electrical connector and attach the wiring harness retainer.
108. Install the Modular Engine Lift Bracket.
109. Using a suitable floor crane, remove the engine from the engine stand.
110. NOTICE: 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.
111. NOTE: The crankshaft rear seal retainer plate does not have a sealant groove. Gasket maker must be applied to the crankshaft rear seal retainer plate mating surface on the engine block.
Apply a bead of gasket maker to the crankshaft rear seal retainer mating surface on the engine block.
112. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
113. Tighten the 6 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
114. NOTICE: 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.
115. NOTE: If 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. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
116. NOTE: If 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. 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.
117. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
118. Tighten the 16 bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
119. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the 2 Crankshaft Rear Seal Installers, install a new crankshaft rear seal.
120. Using the 2 Crankshaft Rear Seal Installers and the Crankshaft Oil Slinger Installer, install the crankshaft rear oil slinger.
121. Install the spacer plate.
122. Position the flexplate and install the 6 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
