Part 2

Oil Pan Extension
Special Service Tool

Rear Crankshaft Seal Installer, 303-1442

Special Service Tool

Rear Crankshaft Cover Alignment Tool, 303-1443
4 Remove the special tools.

NOTE:
Tighten the bolts in the indicated sequence.

Torque to: 11 Nm

Torque to: 11 Nm

NOTE:
The high-pressure fuel pumps are removed from the illustration for clarity.

NOTE:
Lubricate the fuel rail high-pressure fuel pump bucket with clean engine oil.

CAUTION: Tighten the Torx screws a turn at a time until the correct torque is achieved.

NOTE:
Lubricate the fuel rail high-pressure fuel pump O-ring seal with clean engine oil.

Torque to: 11 Nm

5 Loosen the Torx screws half a turn each.

NOTE:
Lubricate the fuel rail high-pressure fuel pump bucket with clean engine oil.

6 Loosen the Torx screws half a turn each.

CAUTION: Care must be taken when positioning the fuel rail high-pressure fuel pump cover to one side.

NOTE:
Fuel rail high-pressure fuel pump cover shown removed for clarity.

Torque to: 11 Nm

CAUTION: Install new high-pressure fuel supply lines.

CAUTION: Lubricate only the union threads with clean engine oil.

NOTE:
Remove and discard the blanking caps.

NOTE:
Install the bolt and unions fully finger tight before final tightening.
7 Do not fully tighten at this stage.

Torque to: 21 Nm

NOTE:
Install the bolt and unions finger tight before final tightening.

NOTE:
Remove and discard the blanking caps.
Unions: 21 Nm
M6: 11 Nm

CAUTION: Make sure that a new component is installed.

Torque to: 21 Nm

Unions: 21 Nm
M6: 8 Nm

Torque to: 22 Nm

Torque to: 25 Nm

CAUTION: Install all the bolts finger tight before final tightening.

Torque to: 25 Nm

Torque to: 12 Nm

Step 1: 45 Nm

Step 2: 60 degree

CAUTION: Install all the bolts finger tight before final tightening.

NOTE:
Tighten the bolts in the indicated sequence.

Torque to: 48 Nm

CAUTION: Install all the bolts finger tight before final tightening.

CAUTION: The bolts can only be used 3 times, mark the bolts with a center punch. If 2 punch marks are visible, discard the bolts.

CAUTION: Install the bolts in the noted position.

NOTE:
Make sure that the crankshaft is not rotated.

NOTE:
Make sure the crankshaft and flexplate mating faces are clean before installation.

NOTE:
Tighten the retaining bolts working diagonally.

Step 1: 45 Nm

Step 2: 90 degree

Torque to: 48 Nm
8 Install a new O-ring seal to the differential case.

CAUTION: Make sure the O ring seal remains in its fitted position.

CAUTION: Make sure that new bolts are installed.
9 With assistance, align and secure the front differential case.

10 Tighten the 100 mm length bolts.
Step 1: 50 Nm

Step 2: 90 degree

11 Tighten the 55 mm length bolts.
Step 1: 50 Nm

Step 2: 60 degree

NOTE:
Install the bolt finger tight before final tightening.

Torque to: 40 Nm

Torque to: 25 Nm

Torque to: 25 Nm
For additional information, refer to Crankshaft Pulley Service and Repair

Special Service Tool

Installer, Stretchy Belt, 303-1500

Install the cooling fan belt.
Rotate the engine clockwise twice, making sure that the belt is seated on both pulleys correctly.
Remove the special tool.

Torque to: 25 Nm
For additional information, refer to Engine Installation

12 Lower the vehicle.

13 Connect the battery ground cable.
For additional information, refer to Specifications Battery and Charging System