Part 4

Engine

Special Tool(s)














Material(s)






120. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





121. Install the 2 thermostat housing-to-lower intake manifold bolts.
- Tighten to 10 Nm (89 lb-in).





122. Install the 2 bolts and the 2 LH (Left Hand) CMP (Camshaft Position) sensors.
- Tighten to 10 Nm (89 lb-in).





123. Install the 2 bolts and the 2 RH (Right Hand) CMP (Camshaft Position) sensors.
- Tighten to 10 Nm (89 lb-in).





124. Install the cover and the pin-type retainer.





125. If equipped, install the block heater wiring harness onto the engine.
- Stage 1: Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 180 degrees.
- Stage 2: Tighten the block heater to 40 Nm (30 lb-ft).





126. Install the LH (Left Hand) cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.





127. Install 6 new RH (Right Hand) exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





128. Using a new gasket, install the RH (Right Hand) exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).





129. If equipped with FWD (Front Wheel Drive), using a new gasket, install the RH (Right Hand) catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





130. Install 6 new LH (Left Hand) exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





131. Using a new gasket, install the LH (Left Hand) catalytic converter and 3 new lower LH (Left Hand) catalytic converter manifold-to-cylinder head nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten the 3 lower LH (Left Hand) catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
- Stage 2: Install the 3 new upper nuts and tighten the upper LH (Left Hand) catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).





132. Install the LH (Left Hand) exhaust heat shield and the 3 bolts.
- Tighten to 12 Nm (106 lb-in).





133. NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the threads of the HO2S (Heated Oxygen Sensor) prior to installing.
Install the LH (Left Hand) HO2S (Heated Oxygen Sensor).
- Tighten to 48 Nm (35 lb-ft).





134. Install the generator, the bolt and the nut.
- Tighten to 48 Nm (35 lb-ft).





135. Connect the EOP (Engine Oil Pressure) switch electrical connector and the wiring harness pin-type retainer.





136. Attach the wiring harness retainer to the generator.





137. Connect the generator electrical connector.





138. Connect the generator B+ cable and install the nut.
- Tighten to 7 Nm (62 lb-in).





139. Connect the A/C (Air Conditioning) compressor electrical connector.





140. Connect the CKP (Crankshaft Position) sensor electrical connector.





141. Install the wiring harness grommet.





142. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).





143. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).





144. Install the ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).





145. Connect the CHT (Cylinder Head Temperature) sensor electrical connector.





146. Connect the KS (Knock Sensor) electrical connector.





147. Connect the 2 RH (Right Hand) CMP (Camshaft Position) sensor electrical connectors.





148. Attach the wiring harness retainer.





149. Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the RH (Right Hand) valve cover stud bolts.





150. Connect the 2 VCT (Variable Camshaft Timing) oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness retainers.





151. Attach the 2 wiring harness retainers from the RH (Right Hand) valve cover.





152. Connect the 3 RH (Right Hand) coil-on-plug electrical connectors. ignition coils.






153. Using a new gasket, install the intake manifold and the 7 bolts.

1. Tighten in the sequence shown in 2 stages.

- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.





154. Install the upper intake manifold support bolt.
- Tighten to 10 Nm (89 lb-in).





155. Connect the crankcase ventilation hose to the PCV (Positive Crankcase Ventilation) valve. REFER to Quick Connect Coupling .





156. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.





157. Connect the EVAP (Evaporative Emission) canister vent solenoid and throttle body electrical connectors.

1. Attach the 2 wiring harness pin-type retainers.






158. Attach the wiring harness retainer to the intake manifold.





159. Connect the LH (Left Hand) CMS (Catalyst Monitor Sensor) electrical connector.

1. Install the wiring harness retainer to the rear of the LH (Left Hand) cylinder head.






160. Connect the 2 LH (Left Hand) CMP (Camshaft Position) sensor electrical connectors.





161. NOTE: Coolant hose removed from graphic for clarity.

Attach the wiring harness retainer.





162. Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the LH (Left Hand) valve cover stud bolts.





163. Connect the LH (Left Hand) HO2S (Heated Oxygen Sensor) electrical connector and attach the wiring harness connector pin-type retainer to the LH (Left Hand) valve cover.





164. Attach the 2 wiring harness pin-type retainers.





165. Connect the 2 VCT (Variable Camshaft Timing) oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness pin-type retainers (1 shown).





166. Attach the 3 wiring harness retainers to the LH (Left Hand) valve cover stud bolts.





167. Install the oil level indicator.





168. Connect the 3 LH (Left Hand) coil-on-plug electrical connectors.





169. Install the crankcase vent tube. REFER to Quick Connect Coupling .





170. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the 303-102 (T74P-6316-B) and 303-1251 , install a new crankshaft front seal.





171. NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil.

NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the 303-102 (T74P-6316-B) and 303-335 (T88T-6701-A) , install the crankshaft pulley.





172. Using the 303-D055 (D85L-6000-A) , install the crankshaft pulley washer and new bolt and tighten in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.





173. Install the accessory drive belt tensioner and the 3 bolts..
- Tighten to 11 Nm (97 lb-in).





174. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.

175. If equipped, connect the block heater electrical connector and install the heat shield.





176. Install 303-1245 on the LH (Left Hand) cylinder head.





177. Using 300-OTC1819E and 303-D089 (D93P-6001-A3) , remove the engine from the stand.





178. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position 303-1250 onto the end of the crankshaft and slide a new crankshaft rear seal onto 303-1250.





179. Using the 303-1250 and 205-153 (T80T-4000-W) , install the new crankshaft rear seal.





180. Install the crankshaft sensor ring.





181. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts.
- Tighten in the sequence shown to 80 Nm (59 lb-ft).