Steps 46-87
46. Using the special tool, install the front oil seal.
47. NOTE: If the crankshaft pulley is not installed within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
48. Using the special tool, install the crankshaft pulley.
49. NOTE: Use a suitable strap wrench (303-D055) or equivalent to hold the pulley while tightening the bolt.
Install the crankshaft pulley and tighten the bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
50. Install the coolant pump pulley and the bolts.
51. Install the accessory drive belt.
52. Install the supercharger belt idler support bracket assembly.
53. NOTE: Inspect and install new O-ring seals if necessary.
NOTE: Lubricate the O-rings with clean engine coolant.
NOTE: LH is shown, RH is similar.
Install the coolant bypass tube and mounting bolts.
54. NOTE: LH is shown, RH is similar. Install the coolant bypass tube studs.
55. Inspect the O-ring seals and install new O-ring seals Is necessary.
56. NOTE: Lubricate the O-rings with clean engine coolant.
Install the heater water outlet tube and the mounting bolts.
57. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.
Install the intake manifold, supercharger and fuel supply manifold as an assembly, and tighten the bolts to 10 Nm (89 inch lbs.) in the sequence shown.
58. Position the wiring harness onto the engine and attach it to the four fuel supply manifold studs.
59. Connect the eight fuel injector electrical connectors.
60. NOTE: RH is shown, LH is similar.
Install the RH and LH ignition coils and connect the electrical connectors.
61. Install the harness support bracket.
62. Clip the harness to the bracket.
63. Connect the A/C compressor electrical connector.
64. Connect the crankshaft position (CKP) sensor electrical connector.
65. Install the fuel charging wiring harness bracket bolt.
66. NOTE: LH is shown, RH is similar.
Connect the two radio ignition interference capacitor electrical connectors.
67. Connect the engine coolant temperature (ECT) sensor electrical connector, and attach the harness to the stud.
68. Connect the camshaft position (CMP) sensor electrical connector.
69. NOTE: Install a new exhaust gas recirculation (EGR) valve gasket.
Install the EGR valve and tube as an assembly.
70. Tighten the EGR tube to the exhaust manifolds.
71. Connect the barometric pressure (BARD) sensor electrical connector.
72. Install and connect the positive crankcase ventilation (PCV) hose.
73. Install the PCV valve.
74. Install the vacuum accessory bracket and the mounting bolts.
75. Install the vacuum accessory bracket mounting nut.
76. Position the vacuum harness and connect the vacuum hoses to the back of the supercharger.
77. Connect the vacuum hose to the EGR valve.
78. Connect the vacuum hoses to the fuel pulse damper and the EGR vacuum regulator solenoid.
79. Connect the vacuum hoses to the supercharger bypass vacuum solenoid and the actuator.
80. Connect the vacuum hoses to the differential pressure feedback EGR system.
81. Connect the electrical connectors to the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
82. Install the RH motor mount.
83. NOTE: LH shown, RH similar
Install the special tools.
84. Attach the special tool to a floor crane and the engine, and remove the engine from the stand.
85. Install the separator plate.
86. Install the flywheel and the bolts.
^ Tighten the bolts in the sequence shown.
87. Install the engine.