Part 3

Engine


















Lower Engine Block (View 1)










Lower Engine Block (View 2)










Cylinder Heads and Intake Manifolds













NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

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.

71. Install a new O-ring seal on the oil pump screen and pickup tube.
- Lubricate the O-ring seal with clean engine oil.






72. Install the oil pump screen and pickup tube.
1. Position the oil pump screen and pickup tube.

2. Install the 2 bolts and tighten to 10 Nm (89 lb-in).






73. Install the new gasket in the LH valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.

2. Install the gasket around bolt holes.

3. Install the remaining part of the gasket.






74. NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.

NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head surface using metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.






75. NOTE: Install a new valve cover gasket.
Position the LH valve cover and install the bolts and stud bolts.

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






76. Install the new gasket in the RH valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.

2. Install the gasket around bolt holes.

3. Install the remaining part of the gasket.






77. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.






78. NOTE: Install a new valve cover gasket.
Position the RH valve cover and install the bolts and stud bolts.

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






79. If equipped, install the block heater.
- Tighten to 21 Nm (15 lb-ft).






80. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.

- Tighten to 14 Nm (124 lb-in).






81. Position the coolant pump housing and attach the coolant hose.
- Tighten the clamp to 7 Nm (62 lb-in).






82. Install the 5 coolant pump housing bolts.
- Tighten to 10 Nm (89 lb-in).






83. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.
- Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.






84. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).
Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration.
- Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.






85. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.





86. NOTICE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.

Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.


87. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.





88. Position the oil level indicator and tube and install the stud bolt.
- Tighten to 9 Nm (80 lb-in).






89. Install the 3 bolts and the A/C compressor bracket.
- Tighten to 25 Nm (18 lb-ft).






90. Lubricate the O-ring seal with clean engine oil and install the oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.






91. Position the generator and install the bolt and 2 nuts.
- Tighten to 47 Nm (35 lb-ft).






92. Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






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





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






95. Install a new gasket and the RH exhaust manifold and new nuts.
- Tighten the nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).







Front Wheel Drive (FWD)

96. Install a new gasket and the RH catalytic converter and the 3 new nuts.
- Tighten to 40 Nm (30 lb-ft).






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






All engines

98. NOTE: LH shown, RH similar.
Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
Install the 6 coil-on-plugs and the bolts.
- Tighten to 6 Nm (53 lb-in).






99. 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. Install new gaskets.
Position the lower intake manifold and install the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






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

Install new fuel injector O-rings.
- Separate the fuel injectors from the fuel rail.

- Remove and discard the fuel injector O-rings.

- Install new O-rings and lubricate with clean engine oil.

- Install the fuel injectors onto the fuel rail.






101. Install the 4 bolts and the fuel rail and injectors assembly.
- Tighten to 10 Nm (89 lb-in).






102. 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. Install new gaskets.
Position the upper intake manifold and install the 7 bolts.
- Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.







103. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown), then tighten all the bolts.
- Tighten to 10 Nm (89 lb-in).






104. Connect the 3 LH coil-on-plug electrical connectors.
- Attach the 2 wiring harness retainers.






105. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer to the oil indicator tube.





106. Install the radio interference capacitor and the nut.
- Tighten to 6 Nm (53 lb-in).






107. Connect the LH VCT (Variable Camshaft Timing) electrical connector.





108. Connect the fuel injector wiring harness electrical connector and attach the wiring harness retainer.





109. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.





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





111. Connect the RH VCT (Variable Camshaft Timing) electrical connector and attach the wiring harness retainer to the valve cover stud bolt.





112. Connect the RH coil-on-plug electrical connectors.
- Attach the 2 wiring harness retainers.






113. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.





114. Attach the wiring harness retainer to the upper intake manifold.





115. Connect the PCV valve electrical connector.





116. Connect the EGR regulator electrical connector and attach the wiring retainer.





117. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.





118. Connect the electronic throttle control electrical connector.





119. Connect the 3 engine wiring connectors.
- Connect the engine block Knock Sensor (KS) electrical connector.

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

- Connect the cylinder head KS (Knock Sensor) electrical connector.






120. Position the B+ wiring harness and attach the 2 harness retainers to the valve cover stud bolts.





121. Install the B+ wire and nut on the generator.
- Tighten to 8 Nm (71 lb-in).






122. Connect the generator electrical connector.





123. Connect the A/C compressor clutch electrical connector.





124. NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
Install the lower half of the Engine Lifting Bracket Set.






125. Install the upper half of the Engine Lifting Bracket Set.





126. Install the Engine Lifting Bracket.





127. Install the Engine Lifting Bracket and the Universal Adapter Bracket.





128. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine from the engine stand.