Engine

Special Tool(s)

	2,200# Floor Crane, Fold Away 300-OTC1819E
	Alignment Pins, Cylinder Head 303-1040 (SR-015486)
	Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
	Handle 205-153 (T80T-4000-W)
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)
	Installer, Connecting Rod 303-442 (T93P-6136-A)
	Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A2 plate only)
	Installer, Front Crank Seal and Damper 303-1531
	Installer, Rear Main Seal 303-1250
	Installer, Spark Plug Tube Seal 303-1247/2
	Lifting Bracket, Engine 303-F047 (014-00073) or equivalent
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Engine — Upper End

Engine — Lower End without Oil Cooler

Engine — Lower End with Oil Cooler

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.

NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Section 303-00 .

1. Record the main bearing code found on the front of the engine block.

2. Record the main bearing code found on the rear of the crankshaft.

3. NOTE: This chart is for selecting main bearings 1 and 5 only, the remaining bearings will be selected using a different chart in the next step.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 5.
   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5 bearing.

4. NOTE: This chart is for selecting main bearings 2, 3 and 4 only.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2, 3 and 4.
   • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 2 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select the No. 3 and No. 4 bearings.

5. Install the crankshaft main bearings.
   • Install the crankshaft upper main bearings into the cylinder block.
   • Install the crankshaft lower main bearings and thrust bearing into the bearing caps.
   • Make sure all oil passages are aligned.
   • Lubricate all main bearings with clean engine oil.

6. NOTE: Lubricate the crankshaft bearing journals with clean engine oil.

   Install the crankshaft into the cylinder block.

7. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).

   Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

8. Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap fasteners.

9. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.

10. Tighten the vertical main bearing cap fasteners in the sequence shown, in 4 stages.
    • Stage 1: Tighten fasteners 1 through 20 to 20 Nm (177 lb-in).
    • Stage 2: Tighten fasteners 1 through 10 to 40 Nm (30 lb-ft).
    • Stage 3: Tighten fasteners 11 through 20 to 65 Nm (48 lb-ft).
    • Stage 4: Tighten fasteners 1 through 20 an additional 90 degrees.

11. Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown, in 3 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 30 Nm (22 lb-ft).
    • Stage 3: Tighten an additional 60 degrees.

12. Check the crankshaft end play. For additional information, refer to Section 303-00 .

13. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).

14. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to Section 303-00 .

15. Assemble the pistons. For additional information, refer to Piston in this section.

16. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

17. Make sure the dimple in the piston faces the front of the engine.

18. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

    NOTICE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

    Use the Piston Ring Compressor and the Connecting Rod Installers to install the connecting rod with the upper connecting rod bearing in place.
    • Lubricate the piston and ring with clean engine oil.
    • Lubricate the rod bearings with clean engine oil.

19. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

    Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.

20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

    Position the lower bearing and connecting rod and install the new bolts loosely.

21. Repeat the previous 5 steps for each of the remaining pistons.

22. NOTE: Main bearing caps are removed for clarity.

    Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 38 Nm (28 lb-ft).
    • Stage 3: Tighten an additional 105 degrees.

23. Install the oil pump screen and pickup tube spacer.
    • Tighten to 25 Nm (18 lb-ft).

24. Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil pump over the crankshaft until seated against the block.
    • Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners.

25. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.

    Tighten the fasteners in the sequence shown in 3 stages:
    • Stage 1: Hand tighten.
    • Stage 2: Tighten the bolt (1) to 10 Nm (89 lb-in), the stud bolt (2) to 25 Nm (18 lb-ft), the bolt (3) to 10 Nm (89 lb-in) and the stud bolt (4) to 20 Nm (177 lb-in).
    • Stage 3: Tighten the bolt (1) an additional 45 degrees, the stud bolt (2) an additional 75 degrees, the bolt (3) an additional 45 degrees and the stud bolt (4) an additional 60 degrees.

26. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks.

    Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.

27. Install the crankshaft rear seal retainer plate and the 6 bolts, tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

28. NOTICE: 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    Inspect the oil pan and engine sealing surfaces. Clean the mating surfaces of the engine and oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

29. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.

    NOTE: If the engine front cover has been removed, it is only necessary to apply sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.

    Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.

30. Position the oil pan baffle and gasket.

31. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt.

    Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

32. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

33. NOTE: Fastener location 7 is a stud bolt.

    Install the oil pan and tighten the fasteners in sequence in 3 stages.
    • Stage 1: Tighten to 2 Nm (18 lb-in)
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    • Stage 3: Tighten an additional 45 degrees.

34. NOTE: Install a new oil filter adapter gasket.

    Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten the bolts in 2 stages.
    • Stage 1: Tighten the bolts to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 60 degrees.

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

    If equipped, install a new oil cooler and the threaded fitting.
    • Tighten to 58 Nm (43 lb-ft).

36. NOTE: Do not lubricate the O-ring seal.

    Install a new oil filter.
    • Tighten to 16 Nm (142 lb-in).

37. NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.

    Position the CKP sensor and install the bolt.
    • Tighten to 10 Nm (89 lb-in).

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

39. Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the flange facing forward.

40. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

    NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.

    NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

    NOTE: Do not turn the crankshaft until instructed to do so.

    NOTE: LH shown, RH similar.

    Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

41. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    • Stage 4: Tighten an additional 90 degrees.

42. NOTICE: 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 which make leak paths. Use a plastic scraper to clean the sealing surfaces.

    Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

43. Install 8 new RH exhaust manifold studs.
    • Tighten to 25 Nm (18 lb-ft).

44. Install new gaskets, the RH exhaust manifold and 8 new nuts.
    • Tighten nuts in the sequence shown in 2 stages.
      • Stage 1: Tighten to 24 Nm (18 lb-ft).
      • Stage 2: Tighten to 32 Nm (24 lb-ft).

45. Install the Cylinder Head Temperature (CHT) sensor.
    • Tighten to 11 Nm (97 lb-in).

46. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.

    Using a new O-ring seal, install the coolant outlet pipe.
    • Tighten to 10 Nm (89 lb-in).

47. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    • Stage 4: Tighten an additional 90 degrees.

48. NOTICE: 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 which make leak paths. Use a plastic scraper to clean the sealing surfaces.

    Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

49. Install 8 new LH exhaust manifold studs.
    • Tighten to 25 Nm (18 lb-ft).

50. Install new gaskets, the LH exhaust manifold and 8 new nuts.
    • Tighten nuts in the sequence shown in 2 stages.
      • Stage 1: Tighten to 24 Nm (18 lb-ft).
      • Stage 2: Tighten to 32 Nm (24 lb-ft).

51. Using a new gasket, install the coolant outlet and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

52. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.

    Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.

53. NOTE: Lubricate the camshafts with clean engine oil prior to installation.

    Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

54. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.

55. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time

56. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

57. NOTE: Intake camshaft shown, exhaust camshaft similar.

    Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.

58. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    2. The timing mark on the exhaust VCT assembly should align with the single colored link.

59. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11 o'clock position.

60. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

    Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.
    • If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.

61. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.
    • Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.

62. Install the LH primary timing chain.
    • Align the colored link on the timing chain with the timing mark on the LH VCT assembly.

63. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.

64. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain guide.

    Install the LH timing chain guide and bolt.
    • Tighten to 10 Nm (89 lb-in).

65. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain tensioner arm.

    Install the LH timing chain tensioner arm.

NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.

66. NOTICE: Do not compress the ratchet assembly or damage to the tensioner will occur.

    Compress the primary timing chain tensioner plunger, using an edge of a vise.

67. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.

68. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.

69. Install the LH primary timing chain tensioner and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the holding pin from the tensioner.

70. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.

71. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.

    Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.

72. NOTE: Lubricate the camshafts with clean engine oil prior to installation.

    Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

73. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.

74. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time

75. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

76. NOTE: Intake camshaft shown, exhaust camshaft similar.

    Install the VCT system oil filter in the intake and exhaust camshafts.

77. Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    2. The timing mark on the exhaust VCT assembly should align with the single colored link.

78. Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 1 o'clock position.

79. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

    Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.
    • If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.

80. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts.
    • Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.

81. Install the RH primary timing chain.
    • Align the colored link on the timing chain with the timing mark on the RH VCT assembly.

82. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.

83. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain guide.

    Install the RH timing chain guide and bolt.
    • Tighten to 10 Nm (89 lb-in).

84. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain tensioner arm.

    Install the RH timing chain tensioner arm.

85. Install the RH primary timing chain tensioner and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the holding pin from the tensioner.

86. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.

87. NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

    NOTE: LH shown, RH similar.

    Fully depress the VCT variable force solenoid pins.

88. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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 bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.

89. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

    Using new gaskets, position the engine front cover onto the dowels.
    • Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts finger-tight.

90. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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.

    Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.

91. NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.

    Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.

92. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

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

94. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.

95. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
    • Stage 1: Tighten to 140 Nm (103 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 100 Nm (74 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

96. Install the generator, the bolt and the nut.
    • Tighten to 48 Nm (35 lb-ft).

97. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 48 Nm (35 lb-ft).

98. Attach the 3 wiring harness retainers (2 shown) from the engine front cover and stud bolts.

99. NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.

    Using a new O-ring seal, install the coolant pump and the 4 bolts.
    • Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.

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

101. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.

102. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).

103. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.

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

105. Install the oil level indicator.

106. Install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
     • Connect the LH intake and exhaust CMP sensor electrical connectors.

107. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.

108. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).

109. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.

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

111. Install the RH intake and exhaust CMP sensors and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
     • Connect the RH intake and exhaust CMP sensor electrical connectors.

112. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
     • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.

113. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown, LH similar.

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

114. NOTE: RH shown, LH similar.

     Attach the 9 wiring harness retainers to the RH valve cover and the 10 wiring harness retainers to the LH valve cover.

115. NOTE: RH shown, LH similar.

     Connect the 8 ignition coil electrical connectors.

116. NOTE: RH shown, LH similar.

     Connect the 4 VCT variable force solenoid electrical connectors.

117. Connect the CHT sensor and the CKP sensor electrical connectors.

118. Connect the 2 KS electrical connectors.

119. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.

120. Connect the oil level sensor electrical connector and the 2 wiring harness retainers.

121. Install the Engine Lifting Bracket

122. Using the Floor Crane, remove the engine from the work stand.

123. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

     Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.

124. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.

125. Install the crankshaft sensor ring.

126. NOTE: Flywheel shown, flexplate similar.

     NOTE: The flywheel/flexplate bolts are torque-to-yield design and are not reusable.

     Install the engine separator plate, the flywheel or flexplate and 8 new bolts.
     • Tighten in the sequence shown in 2 stages.
       • Stage 1: Tighten to 20 Nm (177 lb-in).
       • Stage 2: Tighten an additional 60 degrees.

127. NOTE: If installing the original pressure plate, align it using the index marks made during removal.

     NOTE: Always install new pressure plate bolts.

     If equipped, use suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 9 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured.
     • Tighten the pressure plate bolts in 2 stages in a star pattern.
       • Stage 1: Tighten to 63 Nm (46 lb-ft).
       • Stage 2: Tighten an additional 60 degrees.