Steps 100-139
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
NOTE: Stamped steel RH timing chain guide shown, composite guide similar.
Engine Lower (View 1)
Lower Engine Block (View 2)
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can 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. For additional information, refer to Engine System - General Information Procedures.
NOTE: The engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All replacement RH timing chain guides will be the stamped steel design.
100. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
101. 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.
Using new gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
102. Using a new gasket, install the thermostat housing and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
103. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
- Remove the retaining clips and separate the fuel injectors from the fuel rail.
- Remove and discard the O-ring seals.
- Install new O-ring seals and lubricate with clean engine oil.
- Install the fuel injectors and the retaining clips onto the fuel rail.
104. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
All-Wheel Drive (AWD) vehicles
105. Install the catalytic converter bracket and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).
All vehicles
106. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
107. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
108. Install the cover and the pin-type retainer.
109. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
110. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the RH cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees or, if equipped, tighten the block heater to 40 Nm (30 lb-ft).
111. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
112. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
Front Wheel Drive (FWD) vehicles
113. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
All vehicles
114. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
115. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
116. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
117. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).
118. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
119. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
120. Install the Power Steering Pressure (PSP) tube bracket and bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).
121. Install the PSP hose bracket nut.
- Tighten to 9 Nm (80 lb-in).
122. Attach the PSP hose retainer to the engine lifting eye.
123. Install the generator, the nut and the bolt.
- Tighten to 48 Nm (35 lb-ft).
124. Using new O-ring seals, install the A/C manifold and the bolt.
- Tighten to 25 Nm (18 lb-ft).
125. Position the wiring harness onto the engine.
126. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
127. Attach the wiring harness retainer to the generator.
128. Connect the generator electrical connector.
129. Connect the generator B+ cable and install the nut.
- Tighten to 12 Nm (106 lb-in).
130. Connect the A/C compressor electrical connector.
131. Connect the CKP sensor electrical connector.
132. Install the wiring harness grommet.
133. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).
134. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).
135. Install the wiring harness retainer bolt on the rear of the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).
136. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
137. Connect the LH camshaft VCT solenoid electrical connector.
138. Connect the 3 LH coil-on-plug electrical connectors.
139. Connect the LH HO2S electrical connector.
