Part 2

Cylinder Head

















Installation

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





47. NOTE: Use the Strap Wrench to hold the crankshaft pulley.

Install the bolt and washer and tighten the crankshaft pulley bolt in 4 stages.

- Stage 1: Tighten to 120 Nm (89 lb-ft).

- Stage 2: Loosen 360 degrees.

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

- Stage 4: Rotate an additional 90 degrees (one-fourth turn).





48. Position the coolant pump pulley on the coolant pump and install the bolts.
- Tighten to 25 Nm (18 lb-ft).





49. Install the accessory drive belt idler pulley and bolt.
- Tighten to 25 Nm (18 lb-ft).





50. NOTICE: 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 sealant in 2 places where the engine front cover meets the cylinder head.





51. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





52. NOTICE: 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 sealant in 2 places where the engine front cover meets the cylinder head.





53. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





54. NOTE: Lubricate the O-ring seal with clean engine coolant.

Inspect the O-ring seals. Install new seals, if necessary.





55. Install the coolant bypass tube.





56. Install the ground strap on the rear of the RH cylinder head.

1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).

2. Install the ground strap.

3. Install the retaining nut and tighten to 10 Nm (89 lb-in).





57. Install the insert into the LH cylinder head.





58. NOTE: Align the gasket locator tabs to slots in cylinder head.

Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts at the locations shown.





59. Install the 8 ignition coils and tighten the 8 bolts (4 shown).
- Tighten to 6 Nm (53 lb-in).





60. Install the intake manifold bracket and loosely install the bolt and the stud.





61. Install the thermostat.





62. Install the coolant outlet adapter and loosely install the 2 bolts.





63. Tighten the bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





64. Tighten the stud.
- Tighten to 25 Nm (18 lb-ft).





65. Tighten the bolts.
- Tighten to 25 Nm (18 lb-ft).





66. Connect the EGR tube to the EGR valve.
- Tighten to 43 Nm (32 lb-ft).





67. Connect the EGR tube-to-exhaust manifold connector.
- Tighten to 43 Nm (32 lb-ft).





68. Position the fuel charging wiring at 2 locations at the back of the intake manifold.

69. Install the generator and bolts.
- Tighten to 25 Nm (18 lb-ft).





70. Connect the throttle control and the Throttle Position (TP) sensor electrical connector.





71. Install the generator mounting bracket and bolts.
- Tighten to 10 Nm (89 lb-in).





72. Attach the wire harness retainer and connect the generator electrical connector.





73. Connect the electrical connector to the EGR vacuum regulator solenoid.





74. Connect the crankcase ventilation tube.





75. Install the intake manifold shield and bolts.
- Tighten to 10 Nm (89 lb-in).





76. Connect the 8 fuel injector electrical connectors (4 shown).





77. Connect the 8 ignition coil electrical connectors.





78. Connect the Camshaft Position (CMP) sensor electrical connector.





79. Connect the radio interference capacitor electrical connector.





80. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





81. Install the battery cables and the bolt.

82. Install the Engine Lifting Bracket to the RH cylinder head.





83. Install the Engine Lifting Bracket to the LH cylinder head.





84. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.





85. Install the engine/transmission spacer plate.





86. Position the flexplate and install the bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).





87. Install the engine. For additional information, refer to Engine Engine - Installation in the Installation portion.