Steps 56 - 110
56. NOTE: The front cover must be installed and the bolts tightened within six minutes of sealant application.
Apply a 6 mm (0.24 inch) dot of gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
57. NOTE: Fasteners No. 1 and 6 are studs.
Position the front cover and install the bolts and studs in the sequence shown.
58. Using the special tool, install the crankshaft front oil seal.
59. NOTE: The oil pan must be installed and the bolts tightened within six minutes of sealant application.
Apply a 10 mm (0.24 inch) dot of gasket and sealant to the front cover to cylinder block mating surface.
60. NOTE: Fasteners No. 12 and 13 are studs.
Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
61. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 inch)-0.25 mm (0.009 inch) under flush. Assemblies that are between 0.26 (0.01 inch)-0.50 mm (0.019 inch) should be shimmed using either one or two 0.25 mm (0.009 inch) gold shims. Assemblies that are between 0.51 mm (0.20 inch)-0.75 mm (0.029 inch) should be shimmed using either one or two 0.50 mm (0.019 inch) silver shims. If the pan measures greater than 0.75 mm (0.029 inch) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
62. Tighten the oil pan bolts and studs in the sequence shown1
63. Install the oil pressure sensor.
64. Install a new seal on the oil level indicator tube.
65. Install the oil level indicator tube and install the bolt.
66. Install a new oil filter.
67. NOTE: The crankshaft damper must be installed and the bolt tightened within six minutes of sealant application.
Apply gasket and sealant to the end of the crankshaft damper keyway slot.
68. Using the special tool, install the crankshaft vibration damper.
69. Install the crankshaft vibration damper washer and bolt.
- Tighten the bolt in four stages.
- Stage 1: Tighten to 120 Nm (89 ft. lbs.).
- Stage 2: Loosen one full turn (360°).
- Stage 3: Tighten to 50 Nm (37 ft. lbs.).
- Stage 4: Tighten to 90 Nm (66 ft. lbs.).
70. Install new gaskets in the valve covers.
71. NOTE: The valve cover must be installed and the bolts and studs tightened within six minutes of sealant application.
NOTE: LH shown, RH similar.
Apply a 8 mm (0.31 inch) dot of gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
72. NOTE: Fasteners No. 1-6 and 8-10 are studs.
Position the RH valve cover and install the bolts and studs in the sequence shown.
73. NOTE: Fasteners No. 1, 3, 5-8, and 18 are studs.
Position the LH valve cover and install the bolts and studs in the sequence shown.
74. Install the water pump.
- Position the water pump and install the mounting bolts.
- Tighten the bolts in two stages.
- Step 1: Tighten to 10 Nm (89 inch lbs.).
- Step 2: Tighten an additional 90°.
75. Connect the water pump outlet hose.
76. Install the water pump drive belt.
77. Position the Evaporative Emissions (EVAP) tube and install the nuts.
78. Position the RH exhaust manifold and gasket and install the nuts in the sequence shown.
79. Position the LH exhaust manifold and gasket and install the nuts in the sequence shown.
80. Position the fuel charging harness and install the nut.
81. Install new gaskets in the lower intake manifold.
82. Position the lower intake manifold and install the bolts in the sequence shown.
83. Connect the fuel injector electrical connectors.
84. Install the ignition coil, the stud and the nuts.
85. NOTE: LH shown, RH similar.
NOTE: Apply a film of caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
Connect the LH and RH spark plug wires.
86. Connect the LH H02S electrical connector.
87. Clip the harness to the coolant tube.
88. Connect the coolant temperature sensor electrical connectors.
89. Position the knock sensor and install the bolt.
90. Connect the RH radio ignition interference capacitor, ignition coil electrical connector and H02S electrical connectors. Clip the H02S connectors into place.
91. Install new gaskets in the upper intake manifold, if required.
92. Position the upper intake manifold and install the bolts in the sequence shown.
93. Connect the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid electrical connector.
94. Connect the Positive Crankcase Ventilation (PVC) and Evaporative (EVAP) Emissions hose from the upper intake manifold.
95. Connect the Throttle Position (TP) sensor and Idle Air Control (IAC) valve electrical connectors.
96. Connect the Exhaust Gas Recirculation (EGR) tube to the exhaust manifold.
97. Connect the differential pressure feedback Exhaust Gas Recirculation (EGR) transducer electrical connector.
98. Install the Crankshaft Position (CKP) sensor.
1 Install the sensor.
2 Install the bolt.
3 Connect the electrical connector and clip into place.
99. NOTE: The pulley has LH threads.
Install the crankshaft pulley.
100. Remove the special tool.
101. Connect the oil pressure sensor.
102. Connect the harness to the front LH valve cover studs.
103. Connect the Camshaft Position (CMP) sensor electrical connector.
104. Position the A/C compressor bracket and install the bolts.
- Tighten the bolts in two stages.
- Stage 1: Tighten bolts 1 through 5 to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten bolts 1 through 4 an additional 90°.
105. Position the A/C compressor and install the bolts.
106. Connect the A/C compressor.
1 Connect the compressor electrical connector.
2 Connect the pressure sensor electrical connector.
3 Connect the harness to the bracket.
107. Position the power steering pump and install the bolts.
108. Install the generator.
1 Position the generator.
2 Install the studs.
3 Install the bolt.
4 Connect the electrical connector.
109. Install the power steering pressure hose.
110. Install the accessory drive belt.