Part 4

Engine














Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










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.

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.

All engines

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

NOTE: The upper and lower O-ring seals are not interchangeable.

Install new fuel injector O-ring seals.
- Remove the retaining clips and separate the fuel injectors from the fuel rail.

- Remove and discard the O-ring seals.

- Install new O-ring seals and lubricate with clean engine oil.

- Install the fuel injectors and the retaining clips onto the fuel rail.






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






103. Install the coolant bypass hose to the thermostat housing.





104. Install the RH CMP (Camshaft Position) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






105. NOTE: Align the bracket with the index mark made during removal.

Install the upper intake manifold support bracket and the bolt.

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






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






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





108. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.






109. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.

- Tighten the block heater to 40 Nm (30 lb-ft).






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






111. 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).






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






Front Wheel Drive (FWD) vehicles

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






All engines

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






115. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts.
- Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft).

- Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).






116. Install the LH exhaust heat shield and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






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






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






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






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






121. Install the PSP (Power Steering Pressure) tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).






122. 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).






123. Position the wiring harness onto the engine.

124. Connect the EOP (Engine Oil Pressure) switch electrical connector and the wiring harness pin-type retainer.





125. Connect the generator electrical connector.





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






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






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





129. Install the wiring harness grommet.





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