Steps 140-167

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.

140. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.





141. Connect the LH CMP sensor electrical connector.





142. Connect the CHT sensor electrical connector.





143. Connect the 6 fuel injector electrical connectors (3 shown).





144. Connect the KS electrical connector.





145. Connect the RH CMP sensor electrical connector.





146. Connect the coolant bypass hose to the thermostat housing.





147. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

148. Connect the 3 RH coil-on-plug electrical connectors.





149. Connect the RH VCT solenoid electrical connector.





FWD vehicles

150. Connect the RH CMS electrical connector.





All vehicles

151. Connect the PSP switch electrical connector.





152. 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 upper intake manifold and the 6 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





153. Install the upper intake manifold support bracket and the 2 bolts (one shown).
- Tighten to 10 Nm (89 lb-in).





154. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





155. Connect the RH HO2S electrical connector.





156. Attach the wiring harness retainers to the upper intake manifold.





157. Connect the Throttle Body (TB) electrical connector.





158. Connect the PCV hose to the PCV valve.





159. If equipped, position the block heater wiring harness onto the engine.
- Attach the block heater wiring harness retainer to the power steering reservoir hose and the PSP hose.





160. If equipped, connect the block heater electrical connector and install the heat shield.





161. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.





162. Install the Engine Lift Eye on the LH cylinder head.





163. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





164. 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.





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





166. Install the crankshaft sensor ring.





167. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).