Part 3
EngineAssembly (Steps 81-118)
81. Install the knock sensor (KS) and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
82. Inspect the O-rings seals. Install new seals if necessary.
83. Install the coolant bypass tube.
84. Install the ground strap on the rear of the RH cylinder head.
1 Install the stud bolt and tighten to 25 Nm (18 ft. lbs.).
2 Install the ground strap.
3 Install the retaining nut and tighten to 10 Nm (89 inch lbs.).
85. NOTE: Align the gasket locator tabs to slots in cylinder head.
Install new intake manifold gaskets.
86. Install the intake manifold and hand-tighten the 8 bolts at the locations shown.
87. Install the 8 ignition coils and tighten the 8 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
88. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud.
89. Install the thermostat.
90. Install the coolant outlet adapter and loosely install the 2 bolts.
91. Tighten the 9 bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
92. Tighten the stud.
^ Tighten to 25 Nm (18 ft. lbs.).
93. Tighten the 2 coolant outlet adapter bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
94. Connect the throttle control and throttle positioning sensor electrical connector.
95. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
^ Tighten to 40 Nm (30 ft. lbs.).
96. Connect the EGR tube to the exhaust manifold.
^ Tighten to 40 Nm (30 ft. lbs.).
97. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
98. Install the generator and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
99. Install the generator mounting bracket and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
100. Connect the generator electrical connector.
101. Position the vacuum harness and connect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.
102. Install the generator wiring harness anchor to the LH front stud.
103. Connect the crankcase ventilation tube.
104. Install the intake manifold shield and 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
105. Connect the 8 fuel injector electrical connectors.
106. Connect the 8 ignition coil electrical connectors.
107. Connect the camshaft position (CMP) sensor electrical connector.
108. Connect the radio interference capacitor electrical connector.
109. Connect the KS electrical connector and install the harness retainer to the intake manifold.
110. Connect the cylinder head temperature (CHT) sensor electrical connector.
111. Connect the ground wire to the right rear fuel rail stud.
112. Install the battery cables and the bolt.
113. NOTE: RH shown, LH similar.
Install the RH and LH lighting brackets.
114. Remove the engine from the engine stand.
115. Using the special tools, install the crankshaft rear oil seal.
116. Using the special tools, install the crankshaft oil Slinger.
117. Install the engine/transmission spacer plate.
118. Position the flexplate and install the 6 bolts in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs.).