Steps 1-45
Installation
1. NOTE: If the valve cover is not secured 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 follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
Part 1 Of 2:
Part 2 Of 2:
2. Install the engine front cover and tighten the fasteners in the sequence shown, to 25 Nm (18 ft. lbs.).
3. Install the belt idler pulley.
4. Install the coolant pump pulley.
5. Install the wiring harness bracket and nut.
6. Install the wiring harness bracket nut.
7. Connect the power steering hose.
8. Install the supercharger hose and tube assembly, and connect the coolant hoses.
9. Connect the supercharger coolant hose.
10. NOTE: If the valve cover is not secured 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 follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant to the LH side in the areas shown.
11. Install the LH valve cover and loosely install the bolts.
12. Tighten the LH valve cover bolts in the sequence shown.
13. Connect the camshaft position (CMP) sensor electrical connector.
14. Install the mounting bolts and the vacuum accessory bracket.
15. Install the vacuum accessory bracket mounting nut.
16. Connect the vacuum hoses to the fuel pulse damper and the EGR vacuum regulator solenoid, and position the vacuum harness back.
17. Connect the vacuum hoses to the supercharger bypass vacuum solenoid and the actuator.
18. Connect the vacuum hoses to the differential pressure feedback EGR system.
19. Connect the electrical connectors to the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
20. Connect the positive crankcase ventilation (PCV) valve.
21. Position the oil level indicator tube and install the bolt.
22. Install the LH ignition coils.
23. Connect the ignition coil electrical connectors.
24. Install the LH ignition coil cover and the bolts.
25. Install the clutch release cable and install the two screws.
26. Install new bypass tube O-rings and lubricate them, using premium engine coolant.
27. NOTE: LH shown, RH similar.
Install the coolant bypass tube and the bolts.
28. NOTE: LH shown, RH similar.
Install the two coolant bypass tube nuts.
29. Connect the wiring harness anchors and the engine coolant temperature (ECT) sensor.
30. Connect the upper and lower radiator hoses.
31. Install the generator support bracket.
32. Install the generator and the bolt.
33. Attach the B+ cable and install the generator B + terminal nut.
34. Connect the generator electrical connector.
35. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.
36. Connect the CKP sensor electrical connector.
37. Position the power steering pump and install the bolts.
38. Install the oil cooler.
^ Install the oil cooler and the insert.
^ Install the oil bypass filter.
39. Connect the lower radiator hose.
40. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
41. Using the special tool, install the crankshaft front seal.
42. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
43. Using the special tool, install the crankshaft pulley.
44. Install the bolt and washer. Tighten the bolt in four stages.
^ Stage 1: Tighten the bolt to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten the bolt to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten the bolt an additional 85 to 95 degrees.
45. Rotate the belt tensioner and install the accessory drive belt.