Steps 45 - 65

45. NOTE: If the bolt is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant alone the head to block surface as specified.





46. Install new engine front cover gaskets on the engine front cover. Position the engine front cover. Install the fasteners finger tight.





47. Tighten the front cover bolts and stud bolts in the sequence shown to 25 Nm (18 ft. lbs.).





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








49. Using the special tool, install the front oil seal into the engine front cover.






50. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

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





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






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

Install the bolt and washer. Tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.





53. Rotate the camshaft until the lobe is in the upward position.





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





55. Use the special tool to compress the valve spring and install the camshaft roller followers.





56. Install the spark plugs.
^ Tighten to 18 Nm (13 ft. lbs.).

57. Inspect the LH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





58. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the valve cover.






59. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the left valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.





60. Install the left valve cover and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).

61. Inspect the RH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





62. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the valve cover.






63. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the right valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.





64. Install the right valve cover and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





65. Install the oil pump screen cover and tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).