Part 1

Engine Front Cover

Special Tool(s):

Material:

All vehicles

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

1. NOTE: If the engine front cover, engine mount bracket and bolts 7, 8, 17, 18, 21, 22, 23, 24 and 25 are not installed and tightened within 10 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 a 3.0 mm (0.11 inch) bead of silicone gasket and sealant to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket and sealant to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover.

2. Install the engine front cover and bolts 7, 8, 17, 18, 21 and 22.
^ Tighten in sequence to 10 Nm (89 inch lbs.).

3. Install the engine mount bracket and the 3 bolts.
^ Tighten in the sequence shown to 15 Nm (11 ft. lbs.).

4. Tighten the bolts in the following sequence.
^ Tighten bolts 7, 8, 17, 18, 21 and 22 to 24 Nm (18 ft. lbs.).
^ Tighten bolts 23, 24 and 25 to 75 Nm (55 ft. lbs.).

5. NOTE: The remainder of the engine front cover bolts (1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 19 and 20) must be installed and tightened within 60 minutes of the initial sealant application.

Install bolts 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 19 and 20 and tighten in the sequence shown in 2 stages:
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 24 Nm (18 ft. lbs.).

6. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 ft. lbs.).

7. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the special tools, install a new crankshaft front seal.

8. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the special tools, install the crankshaft pulley.

9. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 (ft. lbs.).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.

10. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

11. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

12. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, variable camshaft timing (VCT) seal installation similar.

Using the special tools, install new VCT solenoid and/or spark plug tube seals.

13. NOTE: If the valve cover is not installed and the fasteners tightened within 5 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 a 8 mm (0.31 inch) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.

14. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

15. NOTE: If the valve cover is not installed and the fasteners tightened within 5 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 a 8 mm (0.31 inch) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.

16. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

17. Install the wiring harness retaining bracket and the 2 nuts.
^ Tighten to 9 Nm (80 inch lbs.).

18. Install the power steering pressure (PSP) hose bracket and nut.
^ Tighten to 9 Nm (80 inch lbs.).

19. Attach the PSP hose retainer to the engine lifting eye.

20. NOTE: LH shown, RH similar.

Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 6 Nm (53 inch lbs.).

21. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
22. Connect the 3 LH coil-on-plug electrical connectors.

23. Connect the LH camshaft VCT solenoid electrical connector.

24. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
25. Connect the heated positive crankcase ventilation (PCV) valve electrical connector.

26. Connect the 3 RH coil-on-plug electrical connectors.

27. Connect the RH VCT solenoid electrical connector.

28. Connect the PSP switch electrical connector.

29. Connect the RH catalyst monitor sensor electrical connector.

30. Using new gaskets, install the upper intake manifold and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

31. Install the upper intake manifold support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs.).

32. Install the upper intake manifold support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs.).

33. Attach the wiring harness retainers to the upper intake manifold.

34. Connect the throttle body electrical connector.

35. Connect the PCV hose to the PCV valve.

36. Connect the PCV fitting electrical connector.

37. If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.

38. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.

39. Raise the engine and transaxle assembly into the vehicle.