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, plastic or wood, Scotch-Brite Pads, and disk (EMU Clean-N Strip 2 in. D x 1/2 in. W x 1/4 in. center hole).
b. The front cover, cylinder head and block bolt holes must be cleaned with a 3/16 in. 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 in. drill.
IMPORTANT: 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: 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: 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 new 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 to block, cylinder head and cam cover T-joints to make sure gaps are filled.
c. Apply a 4.0 mm (0.158 in.) bead (refer to the "RTV Sealants" in Description and Operation of Engine) on the front of the oil pan and a 2.0 mm (0.079 in.) 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: 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 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: 10 Nm (89 in. lbs.)
IMPORTANT: Inspect the cam cover isolators for cracks. Replace the isolators if deterioration exist.
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: 37 Nm (27 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: Install the accessory drive belt idler pulley, if removed.
^ Torque: 27 Nm (20 ft. lbs.)
13. Install generator attachment bolts/nut (both), if removed.
^ Torque: 32 Nm (24 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 and bolts.
Rear bracket to block and compressor:
^ Torque: 25 Nm (19 ft. lbs.)
Front bracket to block and compressor:
^ Torque: 47 Nm (35 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. 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: 50 Nm (37 ft. lbs.)
Upper Mount-to-Frame Rail Bracket:
Torque: 50 Nm (37 ft. lbs.)
18. Install splash shield and wheel.
^ Torque: 140 Nm (103 ft. lbs.)
19. Install the following sensors and components:
^ MAP sensor
- Torque: 5 Nm (44 in. lbs.)
^ Oxygen sensor
- Torque: 25 Nm (19 ft. lbs.)
^ Engine coolant temperature (ECT) sensor and engine temperature sensor
- 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.)
^ EVAP Canister purge
- Torque: 25 Nm (19 ft. lbs.)
^ EGR valve
- Torque: 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: 30 Nm (22 ft. lbs.)
22. Install coolant hoses.
^ Upper radiator
^ Heater
^ Deareation hose at rear side of intake manifold
NOTICE: 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.
IMPORTANT: 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: 6 Nm (53 in. lbs.)
25. 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.)
26. Install air intake resonator, tube, filter cover and clamps. Refer to Fuel Delivery and Air Induction for air induction installation procedures.
27. Connect the battery cables, positive cable first.
^ Torque: 17 Nm (151 in. lbs.)
28. Install oil pan drain plug and fill engine with new oil.
^ Torque: 37 Nm (27 ft. lbs.)
29. Install cylinder block coolant drain plugs and close radiator drain.
^ Torque: 30 Nm (22 ft. lbs.)
30. Fill with coolant. Use only DEX-COOL ethylene glycol-based antifreeze.
IMPORTANT: 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 a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
32. 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.
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.