Part 2 of 2

Engine continued





46. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.





47. Position the oil level indicator and tube and install the stud bolt.
^ Tighten to 10 Nm (89 inch lbs.).





48. Install the bypass tube and the nut and bolt.
^ Tighten to 10 Nm (89 inch lbs.)





49. Position the coolant tube and connect the hoses.





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





51. Connect the hoses.





52. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.





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

Install a new oil cooler.
^ Tighten to 55 Nm (41 ft. lbs.).





54. Lubricate the O-ring seal and install the oil filter.
^ Tighten the oil filter � of a turn after the filter gasket makes contact with the oil filter adapter.





55. Install the coolant hoses and attach them to the retainer.

4x2 vehicles





56. Install the halfshaft support bracket and the bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





57. Install a new gasket and the RH exhaust manifold and nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs.).

All vehicles





58. Install a new gasket and the LH exhaust manifold and nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs.).

59. CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.

Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.





60. Install the LH and RH spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).





61. NOTE: LH shown, RH similar.

NOTE: The valve cover must be installed and the bolts and studs tightened within four minutes of sealant application.

NOTE: Clean cylinder head and front cover surface using metal surface cleaner before applying silicone gasket and sealant.

Apply an 8-mm (0.31 inch) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.





62. Position the LH valve cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





63. Install the coolant pump belt cover and the nuts.
^ Tighten to 6 Nm (53 inch lbs.).





64. Install the engine lift bracket and the bolt.
^ Tighten to 100 Nm (74 ft. lbs.).





65. Position the RH valve cover and install the bolts and stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





66. Install the radio interference capacitor and the nut.
^ Tighten to 6 Nm (53 inch lbs.).





67. NOTE: LH shown, RH similar. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. Install the six coil-on-plugs and the bolts.

^ Tighten to 6 Nm (53 inch lbs.).
68. Install new gaskets in the lower intake manifold.





69. Install the lower intake manifold and the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





70. Position the fuel charging wiring harness and connect the fuel injector electrical connectors.





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





72. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.





73. Connect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and attach the wiring retainers.





74. Connect the LH coil-on-plug electrical connectors and attach the wiring retainers.





75. Connect the radio interference capacitor electrical connector and attach the wiring retainers.





76. Connect the RH coil-on-plug electrical connectors and attach the wiring retainer.





77. Connect the engine coolant temperature (ECT) sensor electrical connector.





78. Install the upper intake manifold and the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





79. Connect the throttle body coolant hose.





80. Connect the vacuum tube fittings to the EGR valve, EGR vacuum regulator and the intake manifold.





81. Install the positive crankcase ventilation (PCV) tube.





82. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors and attach the wiring retainer.





83. Position the engine control wiring harness and install the nuts.
^ Tighten to 6 Nm (53 inch lbs.).





84. Connect the KS electrical connector.





85. Connect the exhaust gas recirculation (EGR) vacuum regulator electrical connector. Attach the wiring harness retainer and install the nut
^ Tighten to 10 Nm (89 inch lbs.).





86. Position the heated oxygen sensor (HO2S) electrical connector bracket. Install the nut and attach the wiring retainer.
^ Tighten to 10 Nm (89 inch lbs.).





87. Attach the engine control sensor wiring connectors to the upper intake manifold.





88. Using the special tools, remove the engine from the engine stand.





89. NOTE: Lubricate the seal lips with clean engine oil before installing.

Using the special tools, install the crankshaft rear oil seal.





90. Position the flexplate and install the bolts.
^ Tighten to 80 Nm (59 ft. lbs.).