Part 5

Engine














Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










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.

All engines

93. Install the engine cover stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).






94. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.

- Tighten to 7 Nm (62 lb-in).






95. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.

- Tighten to 14 Nm (124 lb-in).






96. Using a new gasket, install the oil filter adapter and 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.






97. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).






98. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






99. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.





100. 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).






101. Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






102. 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.






103. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






104. Install the coolant bypass hose to the thermostat housing.





105. Install the RH CMP (Camshaft Position) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






106. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold support bracket 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 cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.

- Tighten the block heater to 40 Nm (30 lb-ft).






111. Install 6 new RH exhaust 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).






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






Front Wheel Drive (FWD) vehicles

114. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).






All engines

115. Install 6 new LH exhaust studs.
- Tighten to 12 Nm (106 lb-in).