Part 3

Engine

Assembly (Steps 83-109)

83. Install the engine plug bolt.
^ Tighten to 20 Nm (15 ft. lbs.)





84. 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.

Clean the valve cover gasket surface with metal surface cleaner.

85. Apply silicone gasket and sealant to the locations shown.





86. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.)





87. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 ft. lbs.)
^ Tighten the spark plugs to 12 Nm (9 ft. lbs.)





88. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the coil-on-plugs, bolts and the crankcase vent tube.
^ Tighten to 8 Nm (71 inch lbs.)





89. Install the 3 engine cover studs.





90. If equipped, install the block heater.
^ Tighten to 21 Nm (15 ft. lbs.)





91. Install the coolant hoses.





92. NOTE: Clean the gasket mating surfaces with metal surface cleaner.

Install the oil filter adapter with a new gasket.
^ Tighten to 25 Nm (18 ft. lbs.)





93. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator and the KS.
^ Tighten the oil separator bolts to 10 Nm (89 inch lbs.)
^ Tighten the KS to 20 Nm (15 ft. lbs.)





94. Install the coolant hose.





95. NOTE: Clean and inspect the thermostat housing gasket. Replace if necessary.

Install the thermostat housing.
^ Tighten to 10 Nm (89 inch lbs.)





96. Install the coolant hose.





97. NOTE: Clean the coolant pump mating surface with metal surface cleaner.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

Install the coolant pump and bolts.
^ Tighten to 10 Nm (89 inch lbs.)





98. Install the coolant pump pulley and bolts.
^ Tighten to 20 Nm (15 ft. lbs.)





99. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.





100. Connect the radio ignition interference capacitor electrical connector.





101. If equipped, connect the block heater electrical connector.





102. Connect the CHT sensor and install the rubber boot.

103. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





104. Install the accessory drive belt tensioner.
^ Tighten to 25 Nm (18 ft. lbs.)





105. Attach the engine wiring harness pin-type retainer.





106. Install the engine wiring harness connector bracket.
^ Tighten to 15 Nm (11 ft. lbs.)





107. Connect the CKP sensor electrical connector





108. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

109. NOTE: Special bolts are used for installation. Do not use standard bolts.

Install the flywheel and the bolts. Tighten the bolts in the sequence shown in these3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.)
^ Stage 2: Tighten to 80 Nm (59 ft. lbs.)
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.)