Part 3
EngineAssembly (Steps 79-118)
79. Install the intake manifold and hand-tighten the 8 bolts at the locations shown.
80. Install the 8 ignition coils and tighten the 8 bolts.
^ Tighten to 10 Nm (89 inch lbs.)
81. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud.
82. Install the thermostat.
83. Install the coolant outlet adapter and loosely install the 2 bolts.
84. Tighten the 9 bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.)
85. Tighten the stud.
^ Tighten to 25 Nm (18 ft. lbs.)
86. Tighten the 2 coolant outlet adapter bolts.
^ Tighten to 25 Nm (18 ft. lbs.)
87. Connect the throttle control and throttle positioning sensor electrical connector.
88. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
^ Tighten to 40 Nm (30 ft. lbs.)
89. Connect the EGR tube to the exhaust manifold.
^ Tighten to 40 Nm (30 ft. lbs.)
90. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
91. Install the generator and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.)
92. Install the generator mounting bracket and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.)
93. Connect the generator electrical connector.
94. 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.
95. Install the generator wiring harness anchor to the LH front stud.
96. Connect the crankcase ventilation tube.
97. Install the intake manifold shield and 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.)
98. Connect the 8 fuel injector electrical connectors.
99. Connect the 8 ignition coil electrical connectors.
100. Connect the camshaft position (CMP) sensor electrical connector.
101. Connect the radio interference capacitor electrical connector.
102. Connect the KS electrical connector and install the harness retainer to the intake manifold.
103. Connect the cylinder head temperature (CHT) sensor electrical connector.
104. Connect the ground wire to the right rear fuel rail stud.
105. Install the battery cables and the bolt.
106. NOTE: RH shown, LH similar.
Install the RH and LH lighting brackets.
107. Remove the engine from the engine stand.
108. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer mating surface on the engine block.
Apply a bead of gasket maker to the rear crankshaft seal retainer mating surface on the engine block.
109. Install the rear oil seal retainer and loosely install the 6 bolts.
110. Tighten the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.)
111. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply the sealant at the rear oil seal retainer to cylinder block sealing surface.
112. Apply sealant at the front cover-to-cylinder block sealing surface.
113. Position the new oil pan gasket, the oil pan and the loosely install the 16 bolts.
114. Tighten the 16 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.)
^ Stage 2: Rotate an additional 60 degrees.
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.)
