Part 3

Engine

Assembly

61. Remove the Crankshaft TDC Timing Peg.





62. Remove Camshaft Alignment Plate.





63. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.
64. Install the Crankshaft TDC Timing Peg.





65. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the special tool.





66. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, the engine valve timing must be corrected.





67. Install the special tool to check the position of the camshafts.
^ If it is not possible to install the special tool, the engine valve timing must be corrected.





68. Remove the special tool.





69. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.





70. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 Nm (62 lb-in).





71. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.





72. Remove the special tool.





73. Install the engine plug bolt.
^ Tighten to 20 Nm (15 lb-ft).





74. CAUTION: 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.

Clean the valve cover gasket surface with metal surface prep.

75. Apply silicone gasket and sealant to the locations shown.





76. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.

Install the valve cover.
^ Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).





77. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install the cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 lb-ft).
^ Tighten the spark plugs to 12 Nm (9 lb-ft).





78. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 ignition coil-on-plugs and the 4 bolts.
^ Tighten to 10 Nm (89 lb-in).





79. If equipped, install the engine block heater.
^ Tighten to 21 Nm (15 lb-ft).





80. Install the crankcase vent oil separator and the 8 bolts.
^ Tighten to 10 Nm (89 lb-in).





81. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the KS and the bolt.
^ Tighten to 20 Nm (15 lb-ft).