Assembly

1. Clean the front cover, cylinder block and oil pan mating surfaces:

CAUTION: 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, plastic or wood, Scotch-Brite Pads, and disk (EMU Clean-N Strip 2 inch D x 1/2 inch W x 1/4 inch center hole).
b. The front cover, cylinder head and block bolt holes must be cleaned with a 3/16 inch drill and tap handle. The oil drain back hole must also be free of RTV. The front cover non tapped holes can be cleaned with 3/8 inch drill.

CAUTION: 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.

CAUTION: If removed, the oil pump must be packed with Vaseline petroleum jelly for priming.

2. Install oil pressure regulator and pump cover if removed. Install the regulator using service tool SA9103E and a hammer. The pump should be installed with the chamfer toward the front oil seal. Torque to 11 Nm (97 inch 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 new oil pressure and suction seals into their respective cavities in the cylinder block.

CAUTION: The front cover, oil seal drain back hole, and passage way must be kept free of RTV. Extra RTV is required at oil pan, cylinder head to block, cylinder head and cam cover T-joints to make sure gaps are filled.





c. Apply a 4.0 mm (0.158 inch) bead on the front of the oil pan and a 2.0 mm (0.079 inch) bead on the front cover. Apply RTV around the front cover top, center bolt hole. Install cover immediately.





3. Install the crankshaft retaining tool SA9104E. The tool aligns the generator pump during front cover installation.





4. Install the front cover assembly fasteners.
^ Front Cover (Perimeter and top center) Bolts: Torque to 30 Nm (22 ft. lbs.).
^ Front Cover Lower Center: Torque to 10 Nm (89 inch lbs.).
5. Install the four oil pan fasteners. Torque to 9 Nm (80 inch lbs.).





CAUTION: After the front cover is installed, 6-12 squirts of oil should 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 to 10 Nm (89 inch lbs.).

CAUTION: Inspect the cam cover isolators for cracks. Replace the isolators if deterioration exist.

7. Install water pump pulley, if removed. Torque to 25 Nm (19 ft. lbs.).

CAUTION: 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. Hold the damper with a strap wrench or use a 3/4 inch square x 12 inch long piece of wood wedged between the damper spoke and rear, lower side of cover when torquing the bolt. Torque to 214 Nm (158 ft. lbs.).
9. Install intake manifold support brace bolt located next to generator.
^ Bracket to Block (right-hand) Torque to 45 Nm (33 ft. lbs.).
^ Bracket to Intake Manifold (right-hand) Torque to 30 Nm (22 ft. lbs.)
10. Drain engine oil and change filter. Install drain plug. Torque to 37 Nm (27 ft. lbs.).
11. Verify gap on all spark plugs. Install spark plugs. Torque to 27 Nm (20 ft. lbs.).
12. Install the belt tensioner. Torque to 30 Nm (22 ft. lbs.).

NOTE: Install the accessory drive belt idler pulley, if removed. Torque to 27 Nm (20 ft. lbs.).

13. Install generator attachment bolts/nut (both), if removed. Torque to 32 Nm (24 ft. lbs.).
14. Install power steering pump assembly
^ Brackets to Power Steering Pump Bracket-to-Block. Torque to 30 Nm (22 ft. lbs.).
^ Power Steering Pump Lower Support Bracket-to-Pump. Torque to 30 Nm (22 ft. lbs.).
^ Power Steering Upper Support Bracket-to-Pump and Upper/Lower Support Bracket and Intake Manifold: Torque to 30 Nm (22 ft. lbs.).
15. Install A/C compressor and bolts.
^ Rear bracket to block and compressor: Torque to 25 Nm (19 ft. lbs.).
^ Front bracket to block and compressor: Torque to 47 Nm (35 ft. lbs.).
16. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.

CAUTION: To prevent [1][2]engine front cover and mount damage, the three front upper mount to engine front cover nuts must be tightened down uniformly.





17. Install the two mount to midrail bracket nuts first. Next, install the three front upper mount to [1][2]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 to 50 Nm (37 ft. lbs.).
^ Upper Mount-to-Frame Rail Bracket: Torque to 50 Nm (37 ft. lbs.).
18. Install splash shield and wheel. Torque to 140 Nm (103 ft. lbs.).
19. Install the following sensors and components:
^ MAP sensor. Torque to 5 Nm (44 inch lbs.).
^ Oxygen sensor. Torque to 25 Nm (19 ft. lbs.).
^ Engine Coolant Temperature (ECT) sensor and engine temperature sensor. Torque to 8 Nm (71 inch lbs.).
^ Throttle body assembly. Torque to 31 Nm (23 ft. lbs.).
^ Starter motor to block, if removed. Torque to 37 Nm (27 ft. lbs.).
^ Starter support bracket to axle shaft, if removed. Torque to 30 Nm (22 ft. lbs.).
^ EVAP Canister purge. Torque to 25 Nm (19 ft. lbs.).
^ EGR valve. Torque to 25 Nm (19 ft. lbs.).
20. 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 (TP) sensor.
^ EGR valve.
^ Injectors.
b. Vacuum Hoses:
^ EVAP canister purge.
^ Fuel pressure regulator.
^ Throttle body.
^ PCV.
^ Fresh air.
^ Brake booster.





21. Install accelerator cable bracket and attach throttle cable. Make sure the throttle cable is properly routed and not binding. Torque to 30 Nm (22 ft. lbs.).
22. Install coolant hoses.
^ Upper radiator.
^ Heater.
^ Deareation hose at rear side of intake manifold.

CAUTION: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Car must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female and male ends together until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

NOTE: The service retainers are different in color from the original equipment retainers. The service fuel feed line retainers are clear in color.

23. Lubricate with clean engine oil the male fuel feed line and the male fuel return line connections. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
24. Install fuel line clip to bracket. Torque to 6 Nm (53 inch lbs.).
25. Install intake manifold bracket and attach fuel supply and return line connects.
^ Support Bracket-to-Block (LH): Torque to 30 Nm (22 ft. lbs.).
^ Support Bracket-to-Intake Manifold (LH): Torque to 30 Nm (22 ft. lbs.).
26. Install air intake resonator, tube, filter cover and clamps.
27. Connect the battery cables, positive cable first. Torque to 17 Nm (151 inch lbs.).
28. Install oil pan drain plug and fill engine with new oil. Torque to 37 Nm (27 ft. lbs.).
29. Install cylinder block coolant drain plugs and close radiator drain. Torque to 30 Nm (22 ft. lbs.).
30. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.

NOTE: Vehicle must be level when filling with coolant.

31. Prime fuel system.
a. Cycle ignition on for five seconds and then off for 10 seconds.
b. Repeat step 31a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
32. Start engine and check for leaks.

CAUTION: 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. Lifters that are pumped up may cause PCM misfire codes to set. Continue to operate the engine until the lifters bleed down. Using the PDT, clear codes and malfunction history.

33. Perform a three mile road test.
34. Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been tested.