44 - 91

44. Remove the LH and RH timing chain tensioner piston retaining wires.





45. Remove the crankshaft damper bolt.

Caution: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-2534Y-30M (Color Blue).





46. Install the ignition pulse wheel.





47. Install the special tool to hold the flexplate.
48. Install three gaskets in the front cover.

Note: The front cover must be installed and the bolts tightened within six minutes of sealant application.





49. Apply a 6 mm (0.24 inch) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.

Note: Fasteners No. 1, 3, 4, 8, 10, 11, 14, 15 and 16 are studs.





50. Position the front cover and install the bolts and studs in the sequence shown.





51. Using the special tool, install the crankshaft front oil seal.

Note: The oil pan must be installed and the bolts tightened within six minutes of sealant application.





52. Apply a 10 mm (0.24 inch) dot of silicone gasket and sealant to the front cover to cylinder block mating surface.





53. Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
54. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 inch)-0.25 mm (0.009 inch) under flush. Assemblies that are between 0.26 (0.01 inch) -0.50 mm (0.019 inch) should be shimmed using either one or two 0.25 mm (0.009 inch) gold shims. Assemblies that are between 0.51 mm (0.20 inch)-0.75 mm (0.029 inch) should be shimmed using either one or two 0.50 mm (0.019 inch) silver shims. If the pan measures greater than 0.75 mm (0.029 inch) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.





55. Tighten the oil pan bolts and studs in the sequence shown.





56. Install a new seal on the oil level indicator tube.





57. Install the oil level indicator tube and install the bolt.

Note: The crankshaft damper must be installed and the bolt tightened with in six minutes of sealant application.





58. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.





59. Using the special tool, install the crankshaft vibration damper.





60. Install the crankshaft vibration damper washer and bolt.
1. Tighten the bolt in four stages.
2. Stage 1: Tighten to 120 Nm (89 ft. lbs.).
3. Stage 2: Loosen one full turn (360°).
4. Stage 3: Tighten to 50 Nm (37 ft. lbs.).
5. Stage 4: Tighten to 90 Nm (66 ft. lbs.).
61. Install new gaskets in the valve covers.

Note: The valve cover must be installed and the bolts and studs tightened with in six minutes of sealant application.

Note: LH shown, RH similar.





62. Apply a 8 mm (0.31 inch) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers,





63. Position the RH valve cover and install the bolts and studs in the sequence shown.





64. Position the LH valve cover and install the bolts and studs in the sequence shown.

Note: RH shown, LH similar. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.





65. Install the six coil-on-plugs and install the bolts.
66. Install new gaskets in the lower intake manifold.





67. Position the knock sensor and install the bolt.





68. Remove the special tool.





69. Position the coolant bypass tube and connect the hoses.





70. Install the oil pressure sender and the block heater.





71. Install the oil cooler.





72. Install the radio ignition noise suppressor electrical connector.





73. Install the generator support bracket.





74. Install the power steering pump.





75. Install the power steering pump pulley.





76. Install the oil filter.





77. Connect the coolant hoses at the oil cooler.





78. Install the water pump assembly.





79. Position a new gasket and tighten the exhaust manifold nuts in the sequence shown.





80. Position a new gasket and tighten the exhaust manifold nuts in the sequence shown.





81. Install the engine lift bracket.





82. Position the gasket and install the lower intake manifold.





83. Position and connect the engine control sensor wiring in the locations shown.
1. coils on plugs
2. fuel injectors
3. idle air control
4. crankshaft position sensor





84. Connect the crankshaft and camshaft position sensor electrical connectors.
85. Install new gaskets in the upper intake manifold.





86. Install the upper intake manifold.





87. Connect the vacuum line from the fuel pressure damper.





88. Connect the engine control sensor wiring to the upper intake manifold.





89. Connect the EGR vacuum regulator and the differential pressure feedback EGR electrical connectors.





90. Install the PCV tube.





91. Connect the Idle Air Control (IAC) valve and the Throttle Position (TP) sensor electrical connectors.