Steps 66 - End

66. NOTE: Oil scraper not shown for clarity.

Position the oil pump screen cover and tube and install the bolts.
1 Tighten to 10 Nm (89 inch lbs.).
2 Tighten to 25 Nm (18 ft. lbs.).






67. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the 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.

NOTE: The silicone must be applied on the groove along the retainer plate.

Apply a 4 mm (0.16 inch) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.





68. Install the rear oil seal retainer and install the 6 bolts finger tight.





69. Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).






70. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas 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 in 2 places.






71. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas 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 in 2 places.





72. Position the new oil pan gasket and the oil pan and loosely install the bolts.





73. Tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.





74. Install the RH engine support insulator bracket and the bolts.
^ Tighten to 72 Nm (53 ft. lbs.).





75. Install the LH engine support insulator bracket and the bolts.
^ Tighten to 72 Nm (53 ft. lbs.).





76. Install the coolant tube and the nut.
^ Inspect and install new O-ring seals as necessary.
^ Lubricate the O-ring seals with clean engine coolant.
^ Tighten to 10 Nm (89 inch lbs.).





77. Install the Knock Sensor (KS) and the bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





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





79. Connect the heater coolant hose.





80. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





81. Install new intake manifold gaskets.





82. Install the intake manifold and tighten the bolts in the sequence shown to 25 Nm (18 ft. lbs.).






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

Install the thermostat housing and the bolts.






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

Install all 8 ignition coils and the bolts.
^ Tighten to 6 Nm (53 inch lbs.).





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





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





87. Connect the ground wire.





88. Install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





89. Connect the 2 fuel charging wiring harness retainers and the 8 electrical connectors.





90. Connect the 2 fuel charging wiring harness retainers and the 8 electrical connectors.





91. Install the throttle body adapter and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





92. Connect the coolant hose.





93. Connect the coolant hoses.





94. Connect the KS electrical connector and the wiring harness pin type retainer.





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





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





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





98. Install the Positive Crankcase Ventilation (PCV) tube and connect the vacuum tube to the throttle body adapter.





99. Connect the Throttle Position (TP) sensor and the electronic throttle body electrical connectors.





100. Install the brake booster vacuum hose and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





101. Install the EGR tube to the exhaust manifold and to the EGR system module.
^ Tighten to 40 Nm (30 ft. lbs.).






102. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the water pump.
1 Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump.
2 Position the coolant pump into the engine block.
3 Install the bolts and tighten to 25 Nm (18 ft. lbs.).





103. Position the coolant pump pulley on the coolant pump and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





104. Install the Crankshaft Position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





105. Install the drive belt tensioner and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





106. Install the Camshaft Position (CMP) sensor and the bolt and connect the electrical connector.
^ Tighten to 10 Nm (89 inch lbs.).





107. Install the generator and the bolts.
^ Tighten to 25 Nm (18 inch lbs.).





108. Install the upper generator bracket and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





109. Connect the electrical connectors, install the nut and attach the wiring harness retainer.
^ Tighten to 8 Nm (71 inch lbs.).





110. Install the idler pulleys and the bolts.
^ Tightens to 25 Nm (18 ft. lbs.).





111. Install the upper radiator hose bracket, the radio interference capacitor and the nut.
^ Tighten to 10 Nm (89 inch lbs.).





112. Install the A/C compressor and the nuts.
^ Tighten to 25 Nm (18 ft. lbs.).





113. Attach the wiring harness retainer to the A/C tube.





114. Position the electrical harness and connect the retainers.





115. Install the crankcase air inlet tube.





116. Connect the A/C compressor and CKP sensor electrical connectors.





117. Install the power steering reservoir bracket, radio interference capacitor, ground cable and nut.
^ Tighten to 25 Nm (18 ft. lbs.).





118. Using the special tool, install a new seal on the power steering pressure hose fitting.





119. Install the power steering pump and the bolts.
^ To install, tighten to 20 Nm (15 ft. lbs.).





120. Connect the return and pressure hoses to the power steering pump.
^ Tighten to 65 Nm (48 ft. lbs.).





121. Install the power steering hose support bracket and the nuts.
^ Tighten to 11 Nm (8 ft. lbs.).






122. NOTE: Clean and inspect the mating surfaces and install new gaskets.

Position the oil filter adapter, install the bolts and connect the oil pressure electrical connector.
^ Tighten to 25 Nm (18 ft. lbs.).

123. Install the oil filter.





124. Install the wiring harness bracket and nuts.
^ Tighten to 20 Nm (15 ft. lbs.).

125. Install the drive belt.






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

Install the engine lift brackets.





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





128. Using the special tools, install the crankshaft rear seal.





129. Using the special tools, install the crankshaft rear oil slinger.





130. Install the spacer plate.






131. CAUTION: Special bolts are used for flexplate installation. Do not use standard bolts.

Position the flexplate and install the bolts finger tight.
^ Tighten the bolts in the sequence shown to 80 Nm (59 ft. lbs.).