Steps 66 - End

66. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.

Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten the bolts to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten the bolts to 25 Nm (18 ft. lbs.).





67. Install the 2 8 mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).





68. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Rotate 90 degrees.
^ Stage 2: Rotate an additional 90 degrees.






69. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.

Install the RH cylinder head. Install 8 new 12 mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





70. Install 2 new 8 mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).





71. Tighten the 8 12 mm bolts in the sequence shown in 2 stages.
^ Stage 1: Rotate 90 degrees.
^ Stage 2: Rotate an additional 90 degrees.





72. Using the special tool, install the crankshaft pulley.






73. CAUTION: A new bolt must be used each time it is removed.

Using the special tool, tighten the bolt in 2 stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Rotate an additional 90 degrees.





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






75. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Loosely install the RH camshaft sprocket bolt.





76. Install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).






77. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Loosely install the LH camshaft sprocket bolt.





78. Install the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).

79. Turn the crankshaft one revolution clockwise.






80. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.

NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).

Install the special tool.






81. NOTE: Camshaft timing slots are off center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.






82. NOTE: Leave the top 2 special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.





83. Install the special tool.






84. CAUTION: The right hand camshaft sprocket bolt is a left hand threaded bolt.

Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt to 85 Nm (63 ft. lbs.).





85. Remove the special tool and install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).






86. NOTE: Do not tighten the special tool top 2 clamp bolts. Camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.






87. NOTE: Camshaft timing slots are off center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the rear of the LH cylinder head.





88. Install the special tool.





89. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt to 85 Nm (63 ft. lbs.).





90. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).





91. Rotate the crankshaft until the cam lobe is in the UP position.






92. NOTE: Lubricate the parts with clean engine oil.

Using the special tool, install the roller followers in their original positions.





93. Install a new gasket and the RH exhaust manifold and nuts.





94. Install a new gasket and the LH exhaust manifold and nuts.
^ Tighten to 22 Nm (16 ft. lbs.).






95. NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging.

Install the Knock Sensor (KS) and the bolt.
^ Tighten to 20 Nm (15 ft. lbs.).





96. Install the oil level indicator tube and bolt.





97. Position the thermostat housing and bypass hose on the coolant pump.
1 Install the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).

2 Position the bypass hose clamp.






98. NOTE: RH valve cover shown, LH similar.

Install the valve covers and tighten the bolts.
^ Tighten to 10 Nm (89 ft. lbs.).






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

Install new O-ring seals on each of the fuel connectors.






100. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.

Install the fuel injectors.





101. Install the fuel rail and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).






102. NOTE: LH shown, RH similar.

Install the LH and RH insulator brackets and the bolts.
^ Tighten to 80 Nm (59 ft. lbs.).





103. Install the oil pressure switch.
^ Tighten to 14 Nm (10 ft. lbs.).





104. Install the battery cable and the bolt and connect the oil pressure switch electrical connector.
^ Tighten to 10 Nm (89 inch lbs.).





105. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.





106. Position the engine wiring harness on the engine.





107. Position the engine wiring harness retainer and install the bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





108. Connect the Crankshaft Position (CKP) sensor electrical connectors and new wiring anchors.






109. NOTE: RH shown, LH similar.

Connect the 6 fuel injector electrical connectors.





110. Install the gaskets, intake manifold and the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





111. Connect the Exhaust Gas Recirculation (EGR) system module vacuum hose and electrical connector.
^ Attach the wiring harness pin type retainer.





112. Connect the electronic throttle body and Throttle Position (TP) sensor electrical connectors.





113. Attach the wiring harness pin type retainer and connect the knock sensor electrical connector.





114. Position the fuel tube.

Engines equipped with an oil cooler





115. Install the oil cooler and hoses.
^ Tighten to 57 Nm (42 ft. lbs.).





116. Position the oil cooler hose brackets and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

All engines





117. Position the ignition coil and bracket assembly and install the bolts.
^ Tighten to 10 Nm (89 ft. lbs.).






118. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires.





119. Connect the following electrical connectors:
^ Camshaft Position (CMP) sensor.
^ Ignition coil.
^ Engine Coolant Temperature (ECT) sensor.
^ Ignition radio interference capacitor.
^ Fuel pressure and temperature sensor.





120. Install the generator mounting bracket.
1 Install the generator mounting bracket bolts.
^ Tighten to 42 Nm (31 ft. lbs.).

2 Install the drive belt tensioner and bolt.
^ Tighten to 47 Nm (35 ft. lbs.).





121. Connect the generator electrical connections and the wire harness retainer.
^ Tighten to 8 Nm (71 inch lbs.).





122. Install the accessory bracket and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).





123. Connect the A/C compressor electrical connector and wire harness retainer.





124. Install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





125. Install the A/C hose.
^ Tighten to 20 Nm (15 ft. lbs.).





126. Install the right side lifting bracket.
^ Tighten to 37 Nm (27 ft. lbs.).





127. Install the left side lifting bracket.





128. Using the special tool and a floor crane, remove the engine from the engine stand.






129. NOTE: Be sure that the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use an extra fine emery cloth or an extra fine steel wool with metal surface cleaner.

Lubricate the crankshaft rear oil seal with engine oil and install on the special tool.





130. Using the special tool, install the crankshaft rear oil seal.
131. Install the spacer plate.






132. NOTE: Special bolts are used for flexplate installation. Do not use standard bolts.

Install the flexplate.
^ Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 13 Nm (10 ft. lbs.).
^ Stage 2: Tighten to 71 Nm (52 ft. lbs.).