Part 3
Engine
Engine - Upper End
Engine - Front End
Engine - Lower End
Assembly
91. Position the exhaust manifold heat shield and install the 2 bolts.
- Tighten to 14 Nm (124 lb-in).
92. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.
Position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
93. 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.
94. NOTE: If the valve cover is 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 may cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
95. Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
96. 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.
97. NOTE: If the valve cover is 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 may cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
98. Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
99. NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the new 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.
100. Install the coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).
101. Install the 2 Knock Sensor (KS)s and the bolts.
- Tighten to 20 Nm (177 lb-in).
102. Install the oil level indicator tube and the front bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
103. Install the rear oil level indicator tube bolt.
- Tighten to 10 Nm (89 lb-in).
104. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs and the valve covers.
105. Connect the CKP sensor electrical connector.
106. NOTE: 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.
NOTE: Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
Install the 10 ignition coils and the 10 bolts.
- Tighten to 6 Nm (53 lb-in).
107. Connect the 10 ignition coil electrical connectors.
108. Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
109. Connect the Engine Oil Pressure (EOP) switch electrical connector.
110. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
111. Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
112. Connect the CMP sensor electrical connector.
113. NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to install it.
Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
- Tighten to 133 Nm (98 lb-ft).
114. Using a suitable floor crane, remove the engine from the engine stand.
115. Lower and support the engine assembly on wood blocks.
116. Install the Engine Lifting Bracket.
117. Using a suitable floor crane, raise the engine.
118. 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.
119. 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.
120. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
121. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
122. 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.
123. 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.
124. 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.
125. Install the oil pan gasket and the oil pan and loosely install the 18 bolts.
126. Tighten the 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.
127. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
128. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.
129. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
130. Install the engine. For additional information, refer to Engine Engine - Installation.