Part 2 of 2

Cylinder Heads Continued











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





36. Using the special tools, install the front oil seal into the engine front cover.





37. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





38. Using the special tool, install the crankshaft pulley.





39. NOTE: Use special tool 303-D055 to hold the crankshaft pulley.

Install the crankshaft pulley bolt and washer. Tighten the bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen one full turn (360 degrees).
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
% Stage 4: Tighten an additional 90 degrees (1/4 turn).





40. NOTE: Lubricate the camshaft roller followers, using clean engine oil.

Rotate the crankshaft until the cam lobe is directly away from the roller follower.





41. Install the special tool between the valve spring coils to prevent valve stem seal damage.





42. NOTE: Install the roller followers into their original locations.

Using the special tool to compress the valve spring, install the camshaft roller followers.





43. Install the spark plugs.





44. If a new gasket is being installed, apply adhesive completely around the gasket groove in the LH valve cover.





45. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the LH valve cover gasket surface, in two places, where the engine front cover meets the cylinder head.





46. Install the LH valve cover and tighten the bolts in the sequence shown.





47. If a new gasket is being installed, apply adhesive completely around the gasket groove in the RH valve cover.





48. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the RH valve cover gasket surface, in two places, where the engine front cover meets the cylinder head.





49. Install the RH valve cover and tighten the bolts in the sequence shown.





50. Install the RH engine support insulator bracket and the bolts.





51. Install new intake manifold gaskets.





52. Install the intake manifold and tighten the bolts in the sequence shown.





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

Install the thermostat housing and the bolts.





54. NOTE: Apply dielectric compound to the inside of the coil boots.

Install all eight ignition coils and the bolts.





55. Position the fuel charging wiring harness on the top of the engine.
^ Connect the harness locators to the engine.





56. Connect the ground wire.





57. Position the starter wiring harness and connect the wiring harness retainers.





58. Connect the LH fuel injector and the coil-on-plug electrical connectors. Install the wiring harness retainers.





59. Connect the RH fuel injector, coil-on-plug and ground electrical connectors. Install the wiring harness retainers.





60. Install the throttle body adapter and bolts.





61. Install the bolt.





62. Connect the coolant hose.





63. Connect the coolant hoses.





64. Connect the knock sensor (KS) electrical connector and install the harness retainer to the intake manifold.





65. Connect the cylinder head temperature (CHT) sensor electrical connector.





66. Connect the EGR system module and fuel pressure sensor electrical connectors.





67. Position the vacuum harness on the engine and connect the EGR system module and fuel pressure sensor vacuum fittings.





68. Install the positive crankcase ventilation (PCV) tube and connect the vacuum tube to the throttle body adapter.





69. Connect the throttle position (TP) sensor and the electronic throttle body electrical connectors.





70. Install the brake booster vacuum hose and bolt.





71. Install the exhaust gas recirculation (EGR) tube to the exhaust manifold and the EGR system module.





72. Position the coolant pump pulley on the coolant pump and install the bolts.





73. Connect the camshaft position (CMP) sensor electrical connector.





74. Install the generator and the bolts.





75. Install the idler pulleys and the bolts.





76. Install the generator bracket and the bolts.





77. Connect the Generator electrical connections.





78. Install the upper radiator hose bracket and the radio interference capacitor.





79. Install the crankcase air inlet tube.





80. Position the wiring harness and connect the retainers.





81. Connect the A/C compressor and the crankshaft position (CKP) sensor electrical connector.





82. Install the power steering reservoir bracket, radio interference capacitor, ground cable and nut.





83. Install the power steering pump.





84. Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.





85. Connect the return and pressure hoses to the power steering pump.





86. Install the power steering hose support bracket and the nuts.
87. Connect the oil pressure sensor electrical connector.





88. Install the wiring harness bracket and nuts.
89. Install the accessory drive belt.





90. NOTE: RH is shown, LH is similar.

Install the engine lift brackets.





91. Attach the special tool to a floor crane and the engine, and remove the engine from the engine stand.





92. Install the rear engine cover.





93. Position the flexplate and install the bolts in two stages.
1. Stage 1: Loosely install the bolts.
2. Stage 2: Tighten the bolts in the sequence shown.
94. Install the engine.