Installation
Engine Front CoverInstallation
1. Raise the engine to the installed position.
2. CAUTION: Place clean, lint free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of sealant, including any sealant from the inner surface of the cylinder block, cylinder head and engine front cover.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
Clean the sealing surfaces of the engine front cover and the mating surfaces on the cylinder heads, the cylinder block and the oil pan.
^ Remove any large deposits of silicone or gasket material with a plastic scraper.
^ Apply silicone gasket remover, following package directions and allow to set for several minutes.
^ Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
^ Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
3. Install the special tools.
4. NOTE: If the engine front cover, engine mount bracket and bolts 7, 8, 17, 18, 19, 20, 23, 24 and 25 are not installed and tightened within 10 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 a 3.0 mm (0.11 inch) bead of silicone gasket and sealant to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket and sealant to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover.
5. Install the engine front cover and bolts 7, 8, 17, 18, 19 and 20.
^ Tighten in sequence to 10 Nm (89 inch lbs).
6. NOTE: Do not tighten the bolt at this time.
Lower the engine to allow installation of the engine mount bracket and lower bolt.
^ Install the engine mount bracket and lower bolt as an assembly.
7. Raise the engine to the installed position.
^ Install the 2 upper engine mount bracket bolts.
8. Tighten bolts in sequence to 15 Nm (11 ft. lbs).
9. Tighten the bolts in this sequence.
^ Tighten bolts 7, 8, 17, 18, 19 and 20 to 24 Nm (18 ft. lbs).
^ Tighten bolts 23, 24 and 25 to 75 Nm (55 ft. lbs).
10. Remove the special tools (alignment pins).
11. NOTE: The remainder of the engine front cover bolts (1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22) must be installed and tightened within 60 minutes of the initial sealant application.
Install bolts 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22 and tighten in the sequence shown in 2 stages:
^ Stage 1: Tighten to 10 Nm (89 inch lbs).
^ Stage 2: Tighten to 24 Nm (18 ft. lbs).
12. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 ft. lbs).
13. Install the engine mount and the 3 bolts.
^ Tighten to 90 Nm (66 ft. lbs).
14. Install the 4 engine mount nuts.
^ Tighten to 63 Nm (46 ft. lbs).
15. Install the engine mount brace, nut and bolt.
^ Tighten to 20 Nm (15 ft. lbs).
16. Tighten the transaxle mount through bolt to 175 Nm (129 ft. lbs).
17. NOTE: LH shown, RH similar.
Install the LH and RH VCT solenoids and bolts.
^ Tighten to 10 Nm (89 inch lbs).
18. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
19. Install the power steering reservoir and the 2 nuts.
^ Tighten to 8 Nm (71 inch lbs).
20. Install the degas bottle and the 3 bolts.
^ Tighten to 9 Nm (80 inch lbs).
21. Connect the 3 PCM electrical connectors.
22. Connect the purge valve electrical connector.
23. Install the radio interference capacitor, the ground wire and the nut to the cowl stud.
^ Tighten to 10 Nm (89 inch lbs).
24. Install the radio interference capacitor wire, the ground wire and the nut to the engine front cover stud.
^ Tighten to 10 Nm (89 inch lbs).
25. Install the ground wire and bolt on the engine front cover.
^ Tighten to 10 Nm (89 inch lbs).
26. Connect the 2 engine wiring harness connectors.
27. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
^ Tighten to 6 Nm (53 inch lbs).
28. Install the A/C pressure tube bracket and bolt.
^ Tighten to 8 Nm (71 inch lbs).
29. Connect the A/C suction tube fitting.
^ Install the safety clip onto the fitting.
30. Install the LH and RH valve covers.
31. Install the engine air cleaner and air cleaner outlet pipe.
32. If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.
33. Align the RH halfshaft splines with the intermediate shaft and push the halfshaft on until the circlip locks the shafts together.
^ Pull the inboard halfshaft outward to make sure the circlip is locked.
34. NOTE: Do not tighten the halfshaft nut at this time.
Install the RH halfshaft into the hub and install a new halfshaft nut.
35. Install the RH lower ball joint into the steering knuckle and install the pinch bolt.
^ Tighten to 63 Nm (46 ft. lbs).
36. Install the RH stabilizer bar link into the lower control arm and install the nut.
^ Tighten to 55 Nm (41 ft. lbs).
37. NOTE: Apply the brake to keep the halfshaft from rotating.
Tighten the RH halfshaft nut to 350 Nm (258 ft. lbs).
38. Install and the transaxle bracket and the 3 bolts.
^ Tighten to 90 Nm (66 ft. lbs).
39. Position the roll restrictor and transaxle bracket plate and install the 3 bolts.
^ Tighten to 90 Nm (66 ft. lbs).
40. Tighten the engine roll restrictor-to-subframe through bolt to 103 Nm (76 ft. lbs).
41. Install the roll restrictor heat shield and the 2 nuts.
^ Tighten to 11 Nm (8 ft. lbs).
42. Position the Y-pipe assembly in place and install the 4 nuts.
^ Tighten to 40 Nm (30 ft. lbs).
43. Install the 2 exhaust hangers and tighten the exhaust clamp.
^ Tighten to 40 Nm (30 ft. lbs).
44. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the special tools, install a new crankshaft front seal.
45. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the special tools, install the crankshaft pulley.
46. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees.
47. Install the accessory drive belt, tensioner and the power steering belt.
48. Fill the engine with clean engine oil.
49. Connect the battery ground cable. For additional information, refer to Battery.
50. Evacuate and recharge the air conditioning system. For additional information, refer to Heating and Air Conditioning.