Part 2
Cylinder HeadsInstallation (Steps 44-87)
44. Using the special tool, install the crankshaft pulley.
45. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
Tighten the crankshaft pulley 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: Rotate an additional 90 degrees (1/4 turn).
46. Position the coolant pump pulley on the coolant pump and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
47. Install the accessory drive belt idler pulley and bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
48. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply sealant in 2 places where the engine front cover meets the cylinder head.
49. 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 inch lbs.).
50. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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 gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
52. Inspect the 0-ring seals. Install new seals if necessary.
53. Install the coolant bypass tube.
54. Install the ground strap on the rear of the RH cylinder head.
1 Install the stud bolt and tighten to 25 Nm (18 ft. lbs.).
2 Install the ground strap.
3 Install the retaining nut and tighten to 10 Nm (89 inch lbs.).
55. NOTE: Align the gasket locator tabs to slots in cylinder head.
Install new intake manifold gaskets.
56. Install the intake manifold and hand-tighten the bolts at the locations shown.
57. Install the 8 ignition coils and tighten the 8 bolts.
^ Tighten to 6 Nm (53 inch lbs.).
58. Install the intake manifold bracket and loosely install the bolt and the stud.
59. Install the thermostat.
60. Install the coolant outlet adapter and loosely install the 2 bolts.
61. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
62. Tighten the stud.
^ Tighten to 25 Nm (18 ft. lbs.).
63. Tighten the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
64. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
^ Tighten to 40 Nm (30 ft. lbs.).
65. Connect the EGR tube-to-exhaust manifold connector.
^ Tighten to 40 Nm (30 ft. lbs.).
66. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
67. Install the generator and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
68. Connect the throttle control and the throttle position (TP) sensor electrical connector.
69. Install the generator mounting bracket and bolts.
^ Tighten to 10 Nm (89 inch lbs.).
70. Connect the generator electrical connector.
71. Connect the electrical connector to the EGR vacuum regulator solenoid.
72. Install the generator wiring harness anchor to the LH front stud.
73. Connect the crankcase ventilation tube.
74. Install the intake manifold shield and bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
75. Connect the 8 fuel injector electrical connectors.
76. Connect the 8 ignition coil electrical connectors.
77. Connect the camshaft position (CMP) sensor electrical connector.
78. Connect the radio interference capacitor electrical connector.
79. Connect the cylinder head temperature (CHT) sensor electrical connector.
80. Connect the ground wire to the right rear fuel rail stud.
81. Install the battery cables and the bolt.
82. Install the RH and LH lifting brackets.
83. Remove the engine from the engine stand.
84. Install the engine/transmission spacer plate.
85. Position the flexplate and install the bolts in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs.).
86. Install the engine.
87. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System.
If equipped with fire suppression system, repower the system.