Part 3

Engine

















Upper End - 4.0L SOHC Engine









Lower End - 4.0L SOHC Engine









NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.

NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play. For additional information, refer to Engine.

NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.


101. Install a new gasket, the RH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).





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





103. Install a new gasket, the LH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).





104. NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging.

Install the Knock Sensor (KS) and the bolt.

- Tighten to 20 Nm (177 lb-in).





105. Install the oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).





106. Position the thermostat housing and bypass hose on the coolant pump.

1. Install the 3 bolts.
- Tighten to 11 Nm (97 lb-in).

2. Position the bypass hose clamp.





107. NOTE: RH valve cover shown, LH similar.

Install the valve covers and tighten the 12 bolts.

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





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

Install new O-ring seals on each of the fuel injectors.





109. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.

Install the fuel injectors.





110. Install the fuel rail and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).





111. Position the fuel supply tube and install the bolt.
- Tighten to 6 Nm (53 lb-in).





112. NOTE: LH shown, RH similar.

Install the LH and RH insulator brackets and the 6 bolts.

- Tighten to 80 Nm (59 lb-ft).





113. Install the oil pressure switch.
- Tighten to 13 Nm (115 lb-in).





114. Position the battery cable and harness and attach the retainers.





115. Connect the oil pressure switch electrical connector. Position the battery cable and harness bracket and install the nut.
- Tighten to 20 Nm (177 lb-in).





116. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.





117. Position the engine wiring harness on the engine.

118. Position the engine wiring harness retainer and install the bolt.
- Tighten to 47 Nm (35 lb-ft).





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





120. Connect the fuel rail pressure and temperature sensor and the Camshaft Position (CMP) sensor electrical connector.





121. Connect the Crankshaft Position (CKP) sensor electrical connectors and new wiring anchors.





122. NOTE: RH shown, LH similar.

Connect the 6 fuel injector electrical connectors and attach the wiring harness retainers.





123. 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.

Install the gaskets, the intake manifold and the 8 bolts.

- Tighten to 11 Nm (97 lb-in).





124. Install the exhaust manifold-to-EGR system module tube.
- Tighten to 34 Nm (25 lb-ft).





125. Connect the Electronic Throttle Body (ETB) and Throttle Position (TP) sensor electrical connectors. Attach the wiring harness bracket and install the nut.
- Tighten to 9 Nm (80 lb-in).





126. Connect the EGR system module vacuum hose and electrical connector. Attach the wiring harness pin-type retainer.





127. Attach the wiring harness pin-type retainer and connect the KS electrical connector.





128. Connect the vacuum and PCV hoses to the intake manifold.





129. Install the oil cooler and hose.
- Tighten to 57 Nm (42 lb-ft).





130. Connect the oil cooler hose. Position the oil cooler hose bracket and install the bolt.
- Tighten to 25 Nm (18 lb-ft).





131. Position the ignition coil, bracket and spark plug wires as an assembly and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





132. NOTE: RH spark plug wires removed for clarity.

Attach the wiring harness retainer and connect the coil and radio interference capacitor electrical connectors.





133. NOTICE: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold or the spark plug wires may be damaged.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Attach the LH spark plug wire retainers and connect the LH spark plug wires to the spark plugs.





134. NOTICE: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold or the spark plug wires may be damaged.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Attach the RH spark plug wire retainers and connect the RH spark plug wires to the spark plugs.





135. Position the heater hose tube bracket and the hoses as an assembly and install the bolt.
- Tighten to 23 Nm (17 lb-ft).





136. Connect the hose to the oil cooler.





137. Connect the heater hose to the thermostat housing.





138. Install the generator mounting bracket.

1. Install the 3 generator mounting bracket bolts.
- Tighten to 42 Nm (31 lb-ft).

2. Install the drive belt tensioner and bolt.
- Tighten to 47 Nm (35 lb-ft).





139. Attach the wire harness retainer, connect the generator electrical connector and the B+ cable and install the nut.
- Tighten to 8 Nm (71 lb-in).





140. Install the A/C compressor and power steering pump bracket and the 4 bolts.
- Tighten to 42 Nm (31 lb-ft).





141. Connect the A/C compressor electrical connector and wire harness retainer.





142. Install the ignition coil bracket bolt.
- Tighten to 10 Nm (89 lb-in).





143. Install the right side Engine Lifting Bracket.





144. Install the left side Engine Lifting Bracket.





145. Using the Spreader Bar and a floor crane, remove the engine from the engine stand.





146. NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. The speedy sleeve must be installed with the crankshaft rear seal.

NOTE: Be sure that the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use an extra-fine emery cloth or an extra-fine steel wool with metal surface prep.

Lubricate the crankshaft rear oil seal with engine oil.

147. Install the Adapter for 303-579 and the Crankshaft Rear Oil Seal Screws.





148. Position the crankshaft rear seal with speedy sleeve on the Adapter for 303-579 and the Crankshaft Rear Oil Seal Screws.





149. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear oil seal with speedy sleeve.





150. Install the spacer plate.

151. Install the flexplate-to-crankshaft spacer.

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

Install the flexplate.

- Tighten the 8 bolts in the sequence shown in 3 stages.

- Stage 1: Tighten to 13 Nm (115 lb-in).

- Stage 2: Tighten to 50 Nm (37 lb-ft).

- Stage 3: Tighten an additional 90 degrees.