Part 3

70. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the LH and RH valve cover sealing surfaces.

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

Apply a 5 mm (0.19 inch) dot of silicone gasket sealant to the front cover-to-RH cylinder head joints.





72. NOTE: Install a new gasket in the valve cover.

Position the RH valve cover. Install the 9 bolts and 5 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

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

Apply a 5 mm (0.19 inch) dot of silicone gasket sealant to the front cover-to-LH cylinder head joints.





74. NOTE: Install a new gasket in the valve cover.

Position the LH valve cover. Install the 6 bolts and 8 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





75. Install the RH and LH ignition coils and the 6 bolts.
^ Tighten to 6 Nm (53 inch lbs.).





76. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).





77. Position a new gasket and the LH exhaust manifold and converter. Install the 6 new nuts.
^ Tighten to 20 Nm (15 ft. lbs.).





78. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).





79. Position a new gasket and the RH exhaust manifold and converter. Install the 6 new nuts.
^ Tighten to 20 Nm (15 ft. lbs.).





80. Install the RH engine insulator bracket and the 4 bolts.
^ Tighten to 55 Nm (41 ft. lbs.).





81. Install the generator, nuts and the bolt.
^ Tighten to 48 Nm (35 ft. lbs.).





82. NOTE: Install a new O-ring seal on the M22 bolt and lubricate with clean engine oil.

Position the oil filter adapter and loosely install the bolts. Tighten in 3 stages:
^ Stage 1: Tighten the M22 bolt to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten the M8 bolt to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten the M22 bolt to 155 Nm (114 ft. lbs.).





83. Install a new oil filter.
^ Tighten to 16 Nm (12 ft. lbs.).





84. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil.

Install the oil level indicator tube and the stud bolt.
^ Tighten to 9 Nm (80 inch lbs.).

85. Position the engine wiring harness.





86. Connect the bypass and the coolant pump hoses.





87. Connect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.





88. Connect the LH ignition coil electrical connectors and attach the wiring retainers.





89. Connect the crankshaft position sensor (CKP) electrical connector and attach the wiring retainer.





90. Attach the ground wire and install the nut.
^ Tighten to 20 Nm (15 ft. lbs.).





91. Connect the generator wiring and install the nut.
^ Attach the wiring retainer.
^ Tighten to 8 Nm (71 inch lbs.).





92. Connect the RH ignition coil electrical connectors and attach the wiring retainers.





93. Position the wiring conduit on the valve cover studs and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).





94. NOTE: Clean the sealing surfaces with metal surface prep before installing the upper and lower intake manifold.

Position the new gaskets and the upper and lower intake manifold. Install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





95. Position the power steering pump, reservoir bracket and tubes. Install the 3 nuts.
^ Tighten to 25 Nm (18 ft. lbs.).





96. Install the power steering fluid reservoir bracket nut.
^ Tighten to 9 Nm (80 inch lbs.).





97. Position the power steering fluid reservoir and install the 2 nuts.
^ Tighten to 9 Nm (80 inch lbs.).





98. Position the power steering tube bracket and install the bolt.
^ Tighten to 7 Nm (62 inch lbs.).





99. Position the power steering tube bracket and install the bolt.
^ Tighten to 7 Nm (62 inch lbs.).





100. Connect the RH HO2S and attach the retainer.





101. Connect the fuel charging wiring harness electrical connector.





102. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.





103. Install and connect the positive crankcase ventilation (PCV) tube.





104. Connect the throttle body electrical connector.





105. Connect the exhaust gas recirculation (EGR) system module electrical connector.





106. Position the exhaust gas recirculation (EGR) system module tube.
^ Tighten to 40 Nm (30 ft. lbs.).





107. Connect the camshaft position sensor (CMP) electrical connector, attach the wiring retainers and install the 2 wiring conduit nuts.
^ Tighten to 6 Nm (53 inch lbs.).





108. Connect the oil pressure sensor electrical connector.





109. Connect the LH heated oxygen sensor (HO2S) electrical connector and attach the wiring retainer.





110. Install the A/C compressor bracket and the 5 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





111. Install the A/C compressor, 2 nuts and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





Freestyle only

112. Install the A/C compressor and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





113. Install the A/C compressor shield, 2 nuts and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





All vehicles

114. Connect the LH catalyst monitor sensor electrical connector and attach the wiring retainer.





115. Connect the A/C compressor electrical connector.





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





Freestyle only

117. Install the A/C compressor pulley shield and the 3 retainers.





All vehicles

118. Install the special tool to the RH cylinder head.





119. Install the special tool to the LH cylinder head.





120. 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 special tool.





121. Install the upper half of the special tool.





122. Using the special tools and a suitable engine crane, remove the engine from the engine stand.

123. NOTE: Lubricate the seal lips with clean engine oil before installing.

Using the special tools, install the crankshaft rear oil seal.

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