Part 2
35. NOTE: The crankshaft pulley must be installed within four minutes of applying the sealant.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
36. Using the special tool, install the crankshaft pulley.
37. NOTE: Use special tool 303-009 or a suitable strap wrench to hold the crankshaft pulley.
Install the washer and the bolt. Tighten the bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90°.
38. Install the RH engine mount.
39. NOTE: Only three bolts are required for installation.
Install the power steering pump bolts.
- Position the power steering pump.
- Install the bolts.
40. Install the special tool between the valve spring coils to prevent valve stem seal damage.
41. NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
42. Remove the special tool.
43. NOTE: One spark plug shown, others similar.
Install the spark plugs.
44. NOTE: RH shown; LH similar.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use 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 the locations shown.
45. NOTE: RH is shown; LH similar.
Install the valve covers.
LH Cylinder Head
46. NOTE: Lubricate the O-ring seal with clean engine oil.
Install a new 0-ring.
47. Install the tube.
48. Install the LH exhaust manifold.
- Install a new LH exhaust manifold gasket.
- Install a LH exhaust manifold.
- Tighten the nuts in the sequence shown.
49. Connect the lower end of the exhaust gas recirculation (EGR) tube to the LH exhaust manifold.
RH Cylinder Head
50. Install the RH exhaust manifold.
- Install a new RH exhaust manifold gasket.
- Install a RH exhaust manifold.
- Tighten the nuts in the sequence shown.
Both Cylinder Heads
51. Inspect O-ring seals and install new 0-ring seals as necessary.
52. Install the coolant bypass tube.
1. Install the bypass tube.
2. Install the nut.
53. Install the intake manifold and gaskets. Tighten the bolts in the sequence shown.
54. Install the thermostat and 0-ring. Install a new 0-ring as necessary.
55. Install the coolant outlet adapter.
56. Install the bolts and the generator.
57. Install the upper generator support bracket.
58. Position the power steering reservoir and bracket, then install the bolts.
59. Install the accessory drive belt.
60. Install the radio interference capacitors.
61. Install the ignition coils and bolts.
62. Position the throttle body and install the bolts, tightening in the sequence shown.
63. Connect the vacuum line to the fuel pressure sensor.
64. Install the positive crankcase ventilation (PCV) valve and hose as an assembly.
65. Connect the PCV hose to the base of the throttle body.
66. Connect the EGR tube to the EGR valve.
67. Install the EGR vacuum regulator solenoid.
1. Install the vacuum lines.
2. Install the electrical connector.
3. Install the bolts.
68. Connect the hoses from the differential pressure feedback EGR transducer.
69. Connect the differential pressure feedback EGR electrical connector.
70. Install the breather tube.
71. Install the engine control sensor wiring.
72. install the RH and LH special tool
73. Using the special tools, remove the engine from the stand.
74. Install the separator plate.
75. Install the flywheel.
76. Install the engine. Service and Repair