Part 2 of 2

Engine continued





51. Install the engine plug bolt.

52. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the valve cover gasket surface with metal surface cleaner.





53. Apply silicone gasket and sealant to the locations shown.





54. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).





55. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 ft. lbs.).
^ Tighten the spark plugs to 15 Nm (11 ft. lbs.).





56. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the coil-on-plugs, bolts and the crankcase vent tube.
^ Tighten to 10 Nm (89 inch lbs.).





57. If equipped, install the block heater.
^ Tighten to 21 Nm (15 ft. lbs.).





58. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator and the KS.
^ Tighten the oil separator bolts to 10 Nm (89 inch lbs.).
^ Tighten the KS to 20 Nm (15 ft. lbs.).





59. Install the coolant hoses.





60. Install the coolant hose.





61. Install the coolant hose.





62. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.





63. Attach the wiring harness retainer.





64. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





65. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.





66. Attach the wiring harness retainer.





67. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

Install new fuel injector O-rings.
^ Separate the fuel injectors from the fuel rail.
^ Remove and discard the fuel injector O-rings.
^ Install new O-rings and lubricate with clean engine oil.
^ Install the fuel injectors onto the fuel rail.





68. Position the fuel rail spacers.





69. Install the fuel rail with the fuel injectors and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





70. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.





71. Install the EGR tube.
^ Tighten to 55 Nm (41 ft. lbs.).





72. Position the intake manifold and connect the positive crankcase ventilation hose.





73. NOTE: Inspect and install new intake manifold gaskets, if necessary.

Install the intake manifold gaskets and intake manifold.
^ Tighten the bolts to 18 Nm (13 ft. lbs.).





74. Connect the throttle position (TP) sensor electrical connector.





75. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.





76. Connect the swirl control valve electrical connector.





77. Connect the idle air control (IAC) motor electrical connector.





78. Connect the temperature manifold absolute pressure (TMAP) electrical connector.





79. Connect the KS and attach the 2 wiring harness retainers.





80. Attach the 2 wiring harness retainers.





81. If removed, install the capacitor and bolt.
^ Tighten to 20 Nm (15 ft. lbs.).

82. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

Position the oil filter adapter in a vise and install the oil filter, new oil cooler and oil cooler bolt.
^ Tighten the oil cooler bolt to 34 Nm (25 ft. lbs.).
^ Tighten the oil filter � turn after the oil filter gasket makes contact with the oil filter adapter.





83. NOTE: Clean the gasket mating surfaces with metal surface cleaner.

Install the oil filter adapter with a new gasket and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





84. Connect the oil pressure sensor electrical connector.





85. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil prior to installing.

Install the oil level indicator and bolts.
^ Tighten to 10 Nm (89 inch lbs.).





86. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.

Install the thermostat housing and bolts.
^ Tighten to 10 Nm (89 inch lbs.).





87. Connect the oil cooler hoses.





88. Attach the 2 wiring harness retainers.





89. Install the engine vacuum tube.
^ Connect the engine vacuum tube.
^ Attach the 2 engine vacuum tube retainers.





90. NOTE: Clean the coolant pump mating surface with metal surface cleaner.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

Install the coolant pump and bolts.
^ Tighten to 10 Nm (89 inch lbs.).





91. Install the coolant pump pulley and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





92. If equipped, install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).





93. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).





94. Install the accessory drive belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





95. Install the generator and bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





96. Install the generator cover and nut.





97. Connect the generator electrical connections and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).





98. Install the generator cooling duct and bolt.
^ Tighten to 10 Nm (89 inch lbs.).





99. Connect the CKP sensor electrical connector.
100. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

Vehicles with automatic transaxle





101. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (50 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).

Vehicles with manual transaxle





102. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (50 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).





103. Install the starter motor isolator.





104. Lubricate the transaxle input shaft pilot bearing with front axle grease.





105. Using the special tool, position the clutch disc on the flywheel.

106. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the bolts.
^ Tighten to 27 Nm (20 ft. lbs.) in a star pattern sequence.