Part 3

Engine















Engine Upper











Engine Upper - LH Cylinder Head











Engine Upper - RH Cylinder Head











Engine Front

NOTE: Early build engines shown, late build similar.













Lower Engine Block (View 1)











Lower Engine Block (View 2)









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late built engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.


108. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





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





110. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.





111. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).





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





113. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the RH 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).





114. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





Front Wheel Drive (FWD) vehicles

115. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





All vehicles

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





117. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the LH 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).





118. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





119. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).





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





121. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





122. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).





123. Install the PSP tube bracket and nut to the RH valve cover stud bolt.
- Tighten to 7 Nm (62 lb-in).





124. Install the PSP tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).





125. Install the stud, generator and the nut and the bolt.
- Tighten the generator stud to 12 Nm (106 lb-in).

- Tighten nut and bolt to 48 Nm (35 lb-ft).





126. Position the wiring harness onto the engine.

127. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.





128. Connect the generator electrical connector.





129. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).





130. Connect the A/C compressor electrical connector.
- Attach the A/C compressor wiring harness retainer.





131. Connect the CKP sensor electrical connector.





132. Install the wiring harness grommet.





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





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





135. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

136. Connect the LH camshaft VCT solenoid electrical connector.





137. Connect the 3 LH coil-on-plug electrical connectors.





138. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.





139. Connect the LH CMS electrical connector.





140. Connect the LH CMP sensor electrical connector.





141. Connect the CHT sensor electrical connector.





142. Connect the 6 fuel injector electrical connectors (3 shown).





143. Install the RH cylinder head ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).





144. Connect the KS electrical connector.





145. Connect the RH CMP sensor electrical connector.





146. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

147. Connect the 3 RH coil-on-plug electrical connectors.





148. Connect the RH VCT solenoid electrical connector.





149. Connect the RH HO2S electrical connector.





FWD vehicles

150. Connect the RH CMS electrical connector.





All vehicles

151. Connect the PSP switch electrical connector.





152. 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 a new gasket, install the upper intake manifold and the 6 bolts.

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





153. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer.
- Tighten to 6 Nm (53 lb-in).





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





155. Attach the wiring harness retainers to the upper intake manifold.





156. Connect the Throttle Body (TB) electrical connector.





157. Connect the PCV hose to the PCV valve.





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

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





160. Install the Engine Lift Eye on the LH cylinder head.





161. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





162. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





163. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





164. Install the crankshaft sensor ring.





165. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).