Part 2

Cylinder Head











Installation (Steps 39-77)
39. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.





40. Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).











41. Loosely install the 4 bolts, then tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.





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





43. Using the special tools, install the crankshaft front oil seal into the engine front cover.





44. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and 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.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.





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





46. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.
47. Install the RH side accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
^ Tighten to 25 Nm (18 lb-ft).





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





49. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

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





50. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

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





51. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

52. 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 in 2 places where the engine front cover meets the cylinder head.





53. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





54. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

55. 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 in 2 places where the engine front cover meets the cylinder head.





56. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





57. Install the oil level indicator tube and the bolt.
^ Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 lb-in).





58. Install a new oil filter.

59. NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.
^ Tighten to 6 Nm (53 lb-in).





60. Position the engine wiring harness on the engine.
61. Connect the engine oil pressure (EOP) switch electrical connector.





62. Attach the engine wiring harness retainer to the stud bolt.
^ Connect the LH heated oxygen sensor (HO2S) electrical connector.





63. Connect the knock sensor (KS) electrical connector and pin-type retainer.





64. Attach the cylinder head temperature (CHT) sensor jumper harness electrical connector pin-type retainer.





65. Connect the CHT sensor electrical connector.





66. Attach the engine wiring harness pin-type retainers.





67. Connect the 2 engine wiring harness retainers to the LH valve cover studs.





68. Connect the 3 engine wiring harness retainers to the RH valve cover studs.





69. NOTE: RH shown, LH similar.

Connect the 4 RH and 4 LH ignition coil electrical connectors.





70. Connect the PCV tubes to the RH and LH valve covers.





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





72. Attach the engine wiring harness pin-type retainers.





73. NOTE: RH shown, LH similar.

Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.





74. NOTE: RH shown, LH similar.

Connect the RH and LH camshaft position (CMP) sensor electrical connectors.





75. Install the special tool.





76. Using a suitable floor crane, remove the engine from the engine stand.
77. Install the engine.