Part 2

Cylinder Head














46. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






47. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.





48. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.
Apply silicone gasket sealant in the locations shown.






49. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.

Install the valve covers and the bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






50. NOTE: LH shown, RH similar.
If equipped, install the LH and RH block drain plugs.

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






51. Install the RH engine insulator bracket, the stud bolt, and the 3 bolts.
- Tighten to 80 Nm (59 lb-ft).






52. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator.

- Tighten to 10 Nm (89 lb-in).






53. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Using a new gasket, install the oil filter adapter and the 8 bolts.

- Tighten in the sequence shown:
- Bolts 1 through 6 to 25 Nm (18 lb-ft).

- Bolts 7 and 8 to 50 Nm (37 lb-ft).






54. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Using a new gasket, install the oil cooler and the 6 bolts.

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






55. Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).






56. 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 the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using new intake manifold gaskets, install the intake manifold and the 14 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






57. Connect the intake manifold-to-coolant tube assembly hose.





58. Position the wiring harness assembly onto the engine.

59. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.
Install the 4 LH coil-on-plugs.

- Connect the 4 LH coil-on-plug electrical connectors.






60. Install the LH coil-on-plug cover and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






61. Attach the wiring harness retainers to the LH valve cover stud bolts.





62. Position the LH radio interference capacitor and install the nut.
- Tighten to 10 Nm (89 lb-in).






63. Connect the 4 LH fuel injector electrical connectors.





64. Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.





65. Connect the CMP (Camshaft Position) sensor electrical connector.





66. Connect the Engine Oil Pressure (EOP) switch electrical connector.





67. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.
Install the 4 RH coil-on-plugs.

- Connect the 4 RH coil-on-plug electrical connectors.






68. Install the RH coil-on-plug cover and 2 stud bolts.
- Tighten to 10 Nm (89 lb-in).






69. Install the A/C tube support bracket and nut.
- Tighten to 9 Nm (80 lb-in).






70. Attach the wiring harness retainers to the RH valve cover stud bolts.





71. Attach the wiring harness retainers to the RH coil-on-plug cover stud bolts.





72. Connect the EGR valve electrical connector.





73. Position the RH radio interference capacitor and install the nut.
- Tighten to 10 Nm (89 lb-in).






74. Connect the fuel rail pressure and temperature sensor electrical connector.





75. Connect the 4 RH fuel injector electrical connectors.





76. Connect the PCV valve electrical connector.





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





78. Install the wiring harness retaining bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






79. Connect the bubbler tube from the Supercharger (SC).





80. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.





81. Attach the 2 wiring harness pin-type retainers (1 shown) to the coolant tube assembly bracket.





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





83. Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






84. Connect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.





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





86. Install and connect the crankcase ventilation tube.





87. Install the EGR tube.
- Tighten to 40 Nm (30 lb-ft).






88. Install the 3 SC (Supercharger) drive belt idler pulleys and the 3 bolts.
- Tighten the heavy load idler pulley (closest to centerline of engine) to 48 Nm (35 lb-ft).

- Tighten the smooth idler pulley and the grooved idler pulley to 25 Nm (18 lb-ft).






89. Install the coolant pump pulley and the 4 bolts.
- Do not tighten the bolts at this time.






90. Install the accessory drive belt idler pulley (grooved) and the bolt.
- Tighten to 25 Nm (18 lb-ft).






91. Install the accessory drive belt idler pulley (smooth) and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).






92. Install the accessory drive belt idler pulley and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






93. Install the accessory drive belt tensioner and the bolt.
- Tighten to 25 Nm (18 lb-ft).






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





95. Attach the wiring harness retainer and install the 2 wiring harness brackets and the 2 nuts to the oil pan stud bolts.
- Tighten to 10 Nm (89 lb-in).






96. Install the alternator and the 3 bolts.
- Tighten to 50 Nm (37 lb-ft).






97. Connect the B+ wire to the generator and install the nut.
- Tighten to 8 Nm (71 lb-in).






98. Connect the generator electrical connector.





99. Position the SC (Supercharger) drive belt and install the SC (Supercharger) drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).






100. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





101. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).





102. Connect the coolant hose from the Charge Air Cooler (CAC).





103. Install the thermostat housing assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).






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





105. Connect the 2 upper radiator hoses to the intake manifold.





106. Install the coolant tube bracket nut.





107. Connect the coolant hose to the thermostat housing.





108. Install the Engine Lifting Bracket.





109. Install the Engine Lifting Bracket.





110. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.





111. Install the engine/transmission spacer plate.





112. Tighten the flywheel bolts evenly in the sequence shown to fully seat the flywheel on the crankshaft pilot.
- Tighten to 80 Nm (59 lb-ft).






113. Install the engine into the vehicle. For additional information, refer to Engine Removal.