Part 3

Engine

90. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.
Install the new lower Teflon(R) seals on the narrow end of the Arbor (part of the 310-207), then install the Arbor on the fuel injector tips.





91. NOTICE: Once the Teflon(R) seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

Using the Pusher Tool (part of the 310-207), slide the Teflon(R) seals off of the Arbor and into the groove on the fuel injectors.






92. NOTE: Make sure the Teflon(R) seal is fully seated in the groove on the fuel injector before sizing the seal.
Slide the 303-1567 off the end of the fuel injector to size the seal.





93. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.

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

NOTE: Install the fuel injectors into the cylinder head within 15 minutes due to Teflon(R) seal expansion.
Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals.





94. Install the 4 new fuel injector clips.





95. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
Install the fuel injectors into the fuel rails.





96. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.
Install the fuel rail by push down on the fuel rail face above the injectors and install the 4 bolts and tighten in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





97. Position a new high-pressure fuel tube and hand start the 2 flare nuts in the following order.

1. Hand tighten the high pressure fuel tube-to-fuel rail flare nut.

2. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.






98. Loosely install the high pressure fuel tube bracket bolts.





99. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel rail flare nut in the following 2 stages:
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.





100. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages:
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.





101. Tighten the high-pressure fuel tube bracket bolts to 10 Nm (89 lb-in).





102. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
Install the fuel injection pump noise insulator shield.





103. Install the fuel rail noise insulator, attach the 2 fuel rail wiring harness retainers and connect the 4 fuel injector and FRP (Fuel Rail Pressure) sensor electrical connectors.





104. Connect the coolant bypass hose and attach to the retainer clip.





105. Inspect and install new intake manifold gaskets if necessary.





106. 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.

Position the intake manifold and connect the crankcase ventilation oil separator tube.

- Install the 6 upper intake manifold bolts finger tight.






107. Tighten the 6 intake manifold bolts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).






108. Attach the EVAP (Evaporative Emission) canister purge valve and connect the fuel vapor tube quick connect coupling to the intake manifold. REFER to Quick Connect Coupling - Type 1 .





109. Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





110. Install the generator stud, generator and the nut and 2 bolts.
- Tighten the generator stud to 8 Nm (71 lb-in).
- Tighten the nut and 2 bolts to 25 Nm (18 lb-ft).





111. Install and connect the coolant return hose.





112. Install the A/C (Air Conditioning) compressor and shield and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





113. Using a new O-ring seal, install the coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in)





114. Install the coolant pump pulley and the 3 bolts.

- Do not torque at this time.






115. Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft)





116. NOTICE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or pulleys.

Rotate the accessory drivebelt tensioner counterclockwise and install the accessory drive belt.





117. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).





118. NOTE: After installation, make sure the A/C (Air Conditioning) compressor belt is correctly seated on the crankshaft and the A/C (Air Conditioning) compressor pulleys.

Position the A/C (Air Conditioning) compressor belt onto the A/C (Air Conditioning) compressor pulley and around 303-1252/2 on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C (Air Conditioning) compressor belt.





119. Position the engine wiring harness and attach the wiring harness retainer to the LH (Left Hand) side of the intake manifold.

- Connect the TB (Throttle Body) electrical connector and the wiring harness retainer.






120. Connect and attach the starter motor harness electrical connector.





121. Connect the EOP (Engine Oil Pressure) sensor electrical connector.





122. Connect and attach the 2 KS (Knock Sensor) electrical connectors.





123. Position the generator B+ harness and install the nut.
- Tighten to 17 Nm (150 lb-in).





124. Connect the generator electrical connector and install the generator B+ terminal cover.

- Attach the wiring harness retainer to the RH (Right Hand) side of intake manifold.






125. Connect and attach the electrical connector and the wiring harness pin-type retainer to the RH (Right Hand) upper side of the intake manifold.





126. Install the ground wire and the bolt to the LH (Left Hand) side of the cylinder head.
- Tighten to 10 Nm (89 lb-in).





127. Connect the EVAP (Evaporative Emission) canister purge valve and fuel injection pump electrical connectors.





128. Connect the ECT (Engine Coolant Temperature) sensor electrical connector and attach the CMS (Catalyst Monitor Sensor) electrical connector retainer and the 2 wiring harness retainers.





129. Connect the VCT (Variable Camshaft Timing) oil control solenoids, coil-on-plug assemblies, CMP (Camshaft Position) sensor electrical connectors and wiring harness retainers to valve cover stud bolts.





130. Connect the A/C (Air Conditioning) compressor, CKP (Crankshaft Position) sensor electrical connectors and 2 wiring harness retainers.





131. Install the crankcase vent tube. REFER to Quick Connect Coupling - Type 2 .





132. Remove the engine from the engine stand.

133. NOTE: Special bolts are used for installation. Do not use standard bolts.
If equipped with a automatic transmission, install the flexplate, the 6 new bolts and the 303-103 (T74P-6375-A).
- Tighten in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).





134. NOTE: Special bolts are used for installation. Do not use standard bolts.
If equipped with a manual transmission, install the flywheel, the 6 new bolts and the 303-103 (T74P-6375-A).
- Tighten in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).





135. NOTICE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil film. Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in solvent.
Position the clutch disc on the clutch pressure plate. Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.





136. Using a clutch aligner, position the clutch disc and clutch pressure plate on the flywheel. Install the 6 new clutch pressure plate-to-flywheel bolts in sequence shown.
- Tighten to 29 Nm (21 lb-ft).





137. Remove the clutch aligner.