Steps 51-99

Engine

















Engine - Upper End













Engine - Front End









Engine - Lower End














51. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, install all of the camshaft roller followers.

- Lubricate the camshaft roller followers with clean engine oil prior to installation.





52. 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: 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 may cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.





53. 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.





54. Tighten the 15 engine front cover fasteners in the sequence shown in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).













55. 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.

Using a new O-ring seal, position the coolant pump and install the bolts loosely.

- Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.





56. Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).





57. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.





58. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.





59. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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 in the crankshaft pulley.





60. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





61. Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).

- Stage 2: Loosen 360 degrees.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90 degrees.





62. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





63. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).





64. 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 a new gasket.

Position the oil filter adapter and install the 4 bolts.

- Tighten to 25 Nm (18 lb-ft).





65. 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.

66. NOTE: LH shown, RH similar.

Install 16 new exhaust manifold studs.

- Tighten to 12 Nm (106 lb-in).





67. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Exhaust Manifold - LH:

68. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Exhaust Manifold - RH:

69. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).





70. NOTICE: 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.

71. 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.





72. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

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).





73. NOTICE: 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.

74. 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.





75. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

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).





76. 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 lb-in).





77. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).





78. NOTE: Do not reuse the O-ring seals.

NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.





79. Install the coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).





80. Install the 2 Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).





81. NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.

- Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

- Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.

- Tighten to 6 Nm (53 lb-in).





82. Position the intake manifold vacuum tube support bracket and install the bolt.
- Tighten to 10 Nm (89 lb-in).





83. Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).





84. Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).





85. Install the Engine Lifting Bracket.





86. Using a suitable floor crane, remove the engine from the engine stand.

87. 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. Failure to follow this procedure can cause future oil leakage.

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.

88. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.





89. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.





90. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





91. 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.

92. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.





93. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.





94. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.





95. 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.





96. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the 2 Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.





97. Using the 2 Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear oil slinger.





98. Install the spacer plate.





99. Install the flexplate and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).