Steps 101-145

Engine



















Upper End















Lower End













All vehicles

NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.

NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play.

NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

101. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness.

102. Position the RH engine mount bracket and install the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).





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





104. Install a new gasket, the RH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).





105. Position the LH engine mount bracket and install the 3 bolts.
- Tighten to 80 Nm (59 lb-ft).





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





107. Install a new gasket, the LH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).





108. NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging.

Install the Knock Sensor (KS) and the bolt.

- Tighten to 20 Nm (177 lb-in).





109. Install the oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).





110. Position the thermostat housing and bypass hose on the coolant pump.

1. Install the 3 bolts.
- Tighten to 11 Nm (97 lb-in).

2. Position the bypass hose clamp.





111. Clean the valve covers and cylinder head sealing surfaces with metal surface prep. Inspect and install new gaskets as necessary.

112. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





113. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





114. Connect the coolant hose to the coolant pump, position the bracket and install the bolt.
- Tighten to 45 Nm (33 lb-ft).





115. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Lubricate the O-ring seals with clean engine oil.

Install new O-ring seals on the 6 fuel injectors.





116. Position the fuel rail and injectors and install the 4 bolts.
- Tighten to 23 Nm (17 lb-ft).





117. Position the main engine wiring harness on the engine and install the 3 bolts.
- Tighten to 40 Nm (30 lb-ft).

- Attach the wiring retainers.





118. Connect the 3 RH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.





119. Connect the 3 LH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.





120. Connect the PCV valve electrical connector.





121. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





122. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring retainers.





123. Position the generator and bracket. Install the 2 bolts and the nut.
- Tighten to 47 Nm (35 lb-ft).





124. Install the accessory drive belt tensioner and the bolt.
- Tighten to 47 Nm (35 lb-ft).





125. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.





126. Connect the Camshaft Position (CMP) electrical connector.





127. Position the fuel rail supply tube brackets and install the 2 bolts.
- Tighten the bolt for the upper bracket to 6 Nm (53 lb-in).

- Tighten the bolt for the lower bracket to 10 Nm (89 lb-in).





128. 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.

NOTE: Clean and inspect all sealing surfaces. Inspect and install new intake manifold gaskets as necessary.

Position the intake manifold and install the 8 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





129. Connect the KS electrical connector and attach the wiring retainer.





130. Install the PCV tube.





131. Position the EGR tube. Connect the fitting to the LH exhaust manifold.
- Tighten to 40 Nm (30 lb-ft).





132. Connect the EGR tube fitting to the EGR system module.
- Tighten to 40 Nm (30 lb-ft).





133. Connect the EGR system module and Throttle Position (TP) sensor electrical connectors.





134. Connect the fuel rail pressure and temperature sensor electrical connector and the vacuum tube.





135. Attach the B+ terminal to the generator and install the nut.
- Tighten to 8 Nm (71 lb-in).

- Attach the wiring retainer to the generator.





136. Connect the generator and Throttle Body (TB) electrical connectors.





137. Install the Engine Lifting Bracket to the RH cylinder head.





138. Install the Engine Lifting Bracket to the LH cylinder head.





139. Using the Spreader Bar and Engine Lifting Brackets, remove the engine from the engine stand.





140. NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. Do not remove the speedy sleeve, it must be installed with the crankshaft rear seal.

NOTE: Be sure the crankshaft rear sealing surface is clean and free from any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep.

Lubricate the crankshaft rear oil seal with clean engine oil.

141. Install the Crankshaft Rear Oil Seal Screws and Adapter.





142. Position the crankshaft rear oil seal with speedy sleeve around the Crankshaft Rear Oil Seal Screws and Adapter.





143. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear oil seal with speedy sleeve.





144. Install the spacer plate and if equipped, the flexplate-to-crankshaft spacer.





145. NOTE: New flexplate or flywheel bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the flexplate or flywheel.

- Tighten the 8 new bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 13 Nm (115 lb-in).

- Stage 2: Tighten to 50 Nm (37 lb-ft).

- Stage 3: Tighten an additional 90 degrees.