Part 2

Engine

Upper End Components and Front End Accessory Drive (FEAD) Components

Lower End Components and Coolant Pump

Oil Filter Adapter Assembly

Timing Drive Components and Cylinder Heads

Flywheel and Exhaust Manifolds

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Engine.

51. Repeat the previous step to install all the roller followers.

52. NOTE: RH shown, LH similar.

Install the 8 spark plugs.

- Tighten to 18 Nm (159 lb-in).

53. NOTE: If the engine front cover is 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 result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

54. Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:
Stage 1: Bolts 1 through 14 to 25 Nm (18 lb-ft).
Stage 2: Bolts 15 and 16 to 50 Nm (37 lb-ft).

55. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

56. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.

57. 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.

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

59. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

60. Using the Strap Wrench, 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.

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

62. Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

63. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

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

65. 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 and sealant to the engine front cover-to-cylinder block joints.

66. 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: RH shown, LH similar.

Install the valve covers, bolts and stud bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).

67. NOTE: LH shown, RH similar.

If equipped, install the LH and RH block drain plugs.

- Tighten to 14 Nm (124 lb-in).

68. 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).

69. 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).

70. NOTICE: A new cooler must be installed or severe damage to the engine can occur.

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

Using new gaskets, install a new oil cooler and the 6 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).

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

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

73. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

74. Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).

75. Install the LH engine support insulator bracket and the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).

76. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

77. Install new gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).

78. Install the RH engine support insulator bracket, the stud bolt, and the 3 bolts.
- Tighten to 80 Nm (59 lb-ft).

79. Install the Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).

80. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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).

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

82. Position the wiring harness assembly onto the engine.

83. 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.

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

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

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

87. Connect the 4 LH fuel injector electrical connectors.

88. Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.

89. Connect the CMP sensor electrical connector.

90. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.

91. 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.