Part 5

Engine


















Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










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.




171. Install the wiring harness grommet.





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






173. Install the CKP (Crankshaft Position) heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).






174. Connect the 3 LH ignition coil-on-plug electrical connectors.





175. Connect the Engine Oil Pressure (EOP) switch electrical connector.
- Attach the EOP (Engine Oil Pressure) switch wiring harness retainer to the cylinder head.






176. Connect the 2 LH VCT (Variable Camshaft Timing) solenoid electrical connectors.





177. Install the engine oil level indicator.





178. Install the LH engine support insulator-to-cylinder block bracket and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).






179. Install the RH engine support insulator and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).






180. Install the RH turbocharger mounting bracket and the 2 bolts.
- Tighten finger-tight.






181. NOTE: Lubricate the cylinder block bore with clean engine oil.

NOTE: Apply clean engine oil to the O-ring seal.

NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the installation of the turbocharger oil return tube.

Using a new O-ring seal, install the RH turbocharger oil return tube.






182. NOTE: Install the RH turbocharger coolant return tube in the turbocharger prior to installation.

Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 bolts.

- Tighten finger-tight.






183. Install the RH turbocharger mounting bracket bolt.
- Tighten finger-tight.






184. Tighten the RH turbocharger mounting bolts.
- Tighten to 32 Nm (24 lb-ft).






185. Tighten the RH turbocharger bracket bolt.
- Tighten to 18 Nm (159 lb-in).






186. Tighten the 2 turbocharger mounting bracket bolts.
- Tighten to 10 Nm (89 lb-in).






187. Install the RH turbocharger coolant return tube into the cylinder block.





188. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the following stages.
- Stage 1: Install the bolt for the oil pressure tube side halfway.

- Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.

- Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).

- Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.






189. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.






190. Install the oil supply tube bolt. Tighten in the following stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.






191. Install the RH turbocharger coolant supply tube.





192. Install the LH turbocharger mounting bracket and the 2 bolts.
- Tighten finger-tight.






193. NOTE: Lubricate the cylinder block bore with clean engine oil.

NOTE: Apply clean engine oil to the O-ring seal.

NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the installation of the turbocharger oil return tube.

Using a new O-ring seal, install the LH turbocharger oil return tube.






194. NOTE: Install the LH turbocharger coolant return tube in the turbocharger prior to installation.

Using a new turbocharger exhaust manifold gasket, install the LH turbocharger and the 3 bolts.

- Tighten finger-tight.






195. Install the LH turbocharger mounting bracket bolt.
- Tighten finger-tight.






196. Tighten the LH turbocharger mounting bolts.
- Tighten to 32 Nm (24 lb-ft).






197. Tighten the LH turbocharger bracket bolt.
- Tighten to 18 Nm (159 lb-in).






198. Tighten the 2 turbocharger mounting bracket bolts.
- Tighten to 10 Nm (89 lb-in).






199. Install the LH turbocharger coolant return tube into the cylinder block.





200. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the following stages.
- Stage 1: Install the bolt for the oil pressure tube side halfway.

- Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.

- Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).

- Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.






201. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.






202. Install the oil supply tube bolt. Tighten in the following stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 30 degrees.






203. Install the turbocharger coolant supply tube.





204. NOTE: LH shown, RH similar.

Position the vacuum hose assembly and install the new tie straps.






205. NOTE: LH shown, RH similar.

Position the turbocharger bypass valve on the bracket. Connect the wastegate hose and the 2 vacuum hoses.






206. NOTE: LH shown, RH similar.

NOTE: Heat insulating wrap removed for clarity.

Connect the turbocharger pressure regulator solenoid electrical connectors.






207. Install the RH PCV tube.





208. Install the LH crankcase vent tube.





209. Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






210. Install the Right Front Lifting Eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).






211. Using the Floor Crane and Engine Spreader Bar, remove the engine from the stand.





212. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.






213. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





214. Install the crankshaft sensor ring.





215. Install the spacer plate.





216. Install the flexplate and the 8 bolts and tighten is sequence shown.
- Tighten to 80 Nm (59 lb-ft).