Part 2

Cylinder Head











Installation (Steps 38-74)
38. Using the special tools, install the crankshaft front seal.





39. NOTE: If not secured within 4 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 to the Woodruff key slot on the crankshaft pulley.





40. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.





41. Using the special tool, install the crankshaft pulley.





42. Using the special tool, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 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 degrees.





43. Install the coolant pump and the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).





44. Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





45. Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





46. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.





47. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.

Apply silicone gasket sealant in the locations shown.





48. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.

Install the valve covers and the bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





49. NOTE: LH shown, RH similar.

Install the LH and RH block drain plugs.
^ Tighten to 14 Nm (10 lb-ft).





50. Install the RH engine insulator bracket, the stud bolt, and the 3 bolts.
^ Tighten to 63 Nm (46 lb-ft).





51. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator.
^ Tighten to 10 Nm (89 lb-in).





52. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using a new gasket, install the oil filter adapter and the 8 bolts.
^ Tighten in the sequence shown:
^ Bolts 1 through 6 to 25 Nm (18 lb-ft).
^ Bolts 7 and 8 to 50 Nm (37 lb-ft).





53. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using a new gasket, install the oil cooler and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





54. Install the 3 coolant tube assembly bolts.
^ Tighten to 10 Nm (89 lb-in).





55. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using new intake manifold gaskets, install the intake manifold and the 14 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





56. Connect the intake manifold-to-coolant tube assembly hose.





57. Position the wiring harness assembly onto the engine.

58. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

Install the 4 LH coil-on-plugs.
^ Connect the 4 LH coil-on-plug electrical connectors.





59. Install the LH coil-on-plug cover and the 2 bolts.
^ Tighten to 10 Nm (89 lb-in).





60. Attach the wiring harness retainers to the LH valve cover stud bolts.





61. Install the LH radio interference capacitor and the nut.
^ Tighten to 10 Nm (89 lb-in).





62. Connect the 4 LH fuel injector electrical connectors.





63. Connect the intake air temperature 2 (IAT2) sensor electrical connector.





64. Connect the CMP sensor electrical connector.





65. Connect the engine oil pressure (EOP) switch electrical connector.





66. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

Install the 4 RH coil-on-plugs.
^ Connect the 4 RH coil-on-plug electrical connectors.





67. Install the RH coil-on-plug cover, bolt and stud bolt.
^ Tighten to 10 Nm (89 lb-in).





68. Attach the wiring harness retainers to the RH valve cover stud bolts.





69. Attach the wiring harness to the RH coil-on-plug cover stud bolt.





70. Connect the EGR valve electrical connector.





71. Install the RH radio interference capacitor and the nut.
^ Tighten to 10 Nm (89 lb-in).





72. Connect the fuel rail pressure and temperature sensor electrical connector.





73. Connect the 4 RH fuel injector electrical connectors.





74. Connect the PCV valve electrical connector.