Steps 41-74

41. NOTE: One spark plug shown, others similar.

Install the spark plugs.





42. NOTE: RH side shown, LH side similar.

NOTE: If not secured within four 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 the locations shown.





43. NOTE: RH valve cover shown, LH similar.

Install the valve covers.





LH cylinder head
44. NOTE: Lubricate the O-ring seal with clean engine oil.

Install a new O-ring.





45. Install the oil level indicator tube.





46. Install the LH exhaust manifold.
^ Install a new manifold gasket.
^ Install the LH exhaust manifold.
^ Tighten the nuts in the sequence shown.





47. Connect the lower end of the exhaust gas recirculation (EGR) tube to the LH exhaust manifold.





RH cylinder head
48. Install the RH exhaust manifold.
^ Install a new exhaust manifold gasket.
^ Install the RH exhaust manifold.
^ Tighten the nuts in the sequence shown.





Both cylinder heads
49. Inspect O-ring seals and install new O-ring seals as necessary.





50. Install the coolant bypass tube.
1. Install the bypass tube.
2. Install the nut.





51. Install the intake manifold and gaskets. Tighten the bolts in the sequence shown.





52. Install the thermostat and O-ring.
^ Install a new O-ring as necessary.





53. Install the coolant outlet adapter.





54. Install the bolts and the generator.





55. Install the upper generator support bracket.





56. Position the power steering reservoir and bracket, then install the bolts.





57. Install the accessory drive belt.





58. Install the radio interference capacitors.





59. Install the ignition coils and bolts.





60. Position the throttle body and install the bolts, tightening in the sequence shown.





61. Connect the vacuum line to the fuel pressure sensor.





62. Install the positive crankcase ventilation (PCV) valve and hose as an assembly.





63. Connect the PCV hose to the base of the throttle body.





64. Connect the EGR tube to the EGR valve.





65. Install the EGR vacuum regulator solenoid.
1. Install the vacuum lines.
2. Install the electrical connector.
3. Install the bolts.





66. Connect the hoses from the differential pressure feedback EGR transducer.





67. Connect the differential pressure feedback EGR electrical connector.





68. Install the breather tube.

Part 1 Of 2:

Part 2 Of 2:

69. Install the engine control sensor wiring.





70. Install the RH and LH special tool.





71. Using the special tool, remove the engine from the stand.





72. Install the separator plate.





73. Install the flywheel.
74. Install the engine.