Front Cover and Component Assembly
DOHC FRONT COVER AND COMPONENT ASSEMBLY
1. Clean the front cover, cylinder block and oil pan mating surfaces:
NOTICE: If excessive RTV is applied, or oil builds up in the blind holes, the casting will crack when bolts are installed. Make sure all oil gallery openings and the oil pan are covered with a shop towel to prevent debris entry.
a. RTV is removed from aluminum surfaces using scraper, wire brush, Scotch-Brite� Pads, and disk (3M Clean-N Strip 2 in. D x 1/2 in. W x 1/4 in. center hole).
b. The front cover holes must be cleaned with a 3/16 in. drill and tap handle. The oil drain back hole must also be free of RTV.
NOTICE: Do not use petroleum cleaners such as mineral spirits, they leave a film onto which RTV will not stick.
c. After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol.
NOTICE: The oil pump must be packed with Vaseline petroleum jelly if removed for priming.
2. Install oil pressure regulator and pump cover if removed. Install the regulator using service tool SA91O3E and a hammer. The pump should be installed with the chamfer toward the front oil seal. Torque: 11 Nm (97 in-lbs).
a. If front seal was removed, use service tool SA9104E to install a new seal. Never tap on the seal or seal installer with a hammer.
b. Install the oil pressure and suction seals into their respective cavities in the cylinder block.
NOTICE: The front cover, oil seal drain back hole, and passage way must be kept free of RTV.
NOTICE: Extra RTV is required at oil pan, cylinder head and cam cover T-joints to make sure gaps are filled. The 1992 engine requires an RTV bead around the top, center bolt hole.
c. Apply a 4.0 mm (0.158 in.) bead (refer to the RTV Section) on the front of the oil pan and a 2.0 mm (0.079 in.) bead on the front cover. The 1992 engine requires an RTV bead around the top, center bolt hole. Install cover immediately.
3. Install the crankshaft retaining tool SA91O4E. The tool aligns the gerotor pump during front cover installation.
Fig. 24 Front Cover Tightening Sequence.:
4. Install the front cover assembly fasteners. Front Cover (Perimeter and 1992 top center) Bolts: Torque: 30 Nm (22 ft-lbs). Front Cover Lower Center: Torque: 10 Nm (89 in-lbs).
5. Install the four oil pan fasteners. Oil Pan Torque: 9 Nm (80 in-lbs).
NOTICE: After the front cover is installed, 6-12 squirts of oil can be pumped through the front oil seal drain back hole to make sure it is not plugged.
6. Apply RTV across the cylinder head and front cover "T" joints. The cam cover gasket can be reused if not damaged. Install the cam cover assembly and tighten the fasteners uniformly. Torque: 10 Nm (89 ft-lbs).
7. Install water pump pulley, if removed. Torque: 25 Nm (19 ft-lbs).
NOTICE: Install a thin film of RTV sealant P/N 21006236 between the damper/pulley assembly flange and washer only. The washer and bolt head flange are designed to prevent oil leakage and do not require RTV sealant.
8. Install crankshaft vibration damper/pulley assembly and retaining bolt.
IMPORTANT: Hold the damper with a strap wrench or use a 3/4 in. square x 12 in. long piece of wood wedged between the damper spoke and rear, lower side of cover when torquing the bolt. Torque: 214 Nm (158 ft-lbs).
9. Install intake manifold support brace bolt located next to generator. Bracket to Block (right-hand) Torque: 45 Nm (33 ft-lbs). Bracket to Intake Manifold (right-hand) Torque: 30 Nm (22 ft-lbs).
10. Drain engine oil and change filter. Install drain plug. Torque: 35 Nm (26 ft-lbs).
11. Verify gap on all spark plugs.
a. Install spark plugs. Torque: 27 Nm (20 ft-lbs).
12. Install the belt tensioner. Torque: 30 Nm (22 ft-lbs).
IMPORTANT: On 1992 engines, install the accessory drive belt idler pulley. Torque: 45 Nm (33 ft-lbs).
13. Install generator attachment bolts/nut (both), if removed. Torque: 37 Nm (27 ft-lbs).
14. Install power steering pump assembly and brackets. Power Steering Pump Bracket-to-Block: Torque: 30 Nm (22 ft-lbs). Power Steering Pump Lower Support Bracket-to-Pump: Torque: 30 Nm (22 ft-lbs). Power Steering Upper Support Bracket-to-Pump and Upper/Lower Support Bracket and Intake Manifold: Torque: 30 Nm (22 ft-lbs).
15. Install A/C compressor bolts. Rear bracket to block and compressor: Torque: 25 Nm (19 ft-lbs). Front bracket to block and compressor: Torque: 54 Nm (40 ft-lbs).
16. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.
NOTICE: To prevent engine front cover and mount damage, the three front upper mount to engine front cover nuts must be tightened down uniformly.
17. On a 1992 powertrain with a torque axis mount system, install the two mount to midrail bracket nuts first. Next, install the three front upper mount to engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed. Upper Mount-to-Front Cover: Torque: 70 Nm (52 ft-lbs). Upper Mount-to-Frame Rail Bracket: Torque: 70 Nm (52 ft-lbs).
18. Install splash shield and tire. Torque: 140 Nm (103 ft-lbs).
19. Install the following sensors and electrical harness connectors and vacuum hoses.
a. Electrical Connectors:
^ Grounds (if disconnected)
^ Generator
^ Oxygen sensor
^ Starter
^ Coolant temperature sensors (two separate connectors)
^ A/C compressor
^ Idle air control (IAC)
^ Throttle position switch
^ EGR solenoid
^ Injectors
b. Vacuum Hoses:
^ Canister purge
^ Fuel pressure regulator
^ EGR valve and solenoid
^ Throttle body
^ PCV
^ Fresh air
^ Brake booster
c. Sensor and Component Torques:
^ MAP sensor Torque: 5 Nm (44 in-lbs).
^ Oxygen sensor Torque: 25 Nm (19 ft-lbs).
^ Coolant temperature (two separate sensors) Torque: 8 Nm (71 in-lbs).
^ Throttle body assembly Torque: 31 Nm (23 ft-lbs).
^ Starter motor to block, (if removed) Torque: 37 Nm (27 ft-lbs).
^ Starter support bracket to axle shaft, (if removed) Torque: 30 Nm (22 ft-lbs).
^ Canister purge Torque: 25 Nm (19 ft-lbs).
^ EGR valve Torque: 25 Nm (19 ft-lbs).
20. Install accelerator cable bracket and attach throttle cable. Make sure the throttle cable is properly routed and not binding. Torque: 25 Nm (19 ft-lbs).
21. Install coolant hoses.
^ Upper radiator
^ Heater
^ De-areation hose at rear side of intake manifold
NOTICE: Whenever fuel line connects are disconnected, lubricate steel line male ends with clean engine oil. Holding steel line, firmly press on female connector until click is heard, then pull back to confirm engagement. make sure the fuel line connects are fully seated. Pinched, kinked or damaged fuel lines must be replaced.
22. Install intake manifold bracket and attach fuel supply and return line connects. Support Bracket-to-Block (LH): Torque: 30 Nm (22 ft-lbs). Support Bracket-to-Intake Manifold (LH): Torque: 30 Nm (22 ft-lbs). Fuel Line-to-Pressure Regulator: Torque: 15 Nm (133 in-lbs). Fuel Line-to-Fuel Rail: Torque: 15 Nm (133 in-lbs).
23. Install air intake resonator, tube, filter cover and clamps. Make sure the button is properly located in the service support bracket.
24. Connect the battery cables. Torque: 17 Nm (151 in-lbs).
25. Check oil pan drain plug and fill new engine with new oil. Torque: 35 Nm (26 ft-lbs).
26. Install cylinder block coolant drain plugs and close radiator drain. Torque: 35 Nm (26 ft-lbs).
27. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.
IMPORTANT: Vehicle must be level when filling with coolant.
28. Prime fuel system.
a. Cycle ignition on for 5 seconds and then off for 10 seconds.
b. Repeat step 26a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
29. Start engine and check for leaks.
IMPORTANT: Allow the engine to idle for three to five minutes. If lifters are noisy or cylinders are misfiring, warm the engine up at a low rpm (less than 2,000). After the coolant temperature has reached approximately 85°C (185°F), cycle the engine rpm from idle to 3,000 for approximately 10 minutes or drive the vehicle five miles to purge the air. If the air cannot be purged, the faulty lifter(s) will have to be replaced.
30. Perform a 3 mile road test.
31. Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been tested.