Part 3
92. Install the coolant hose.
93. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
94. Attach the wiring harness retainer.
95. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
96. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
97. Attach the wiring harness retainer.
98. 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.
99. If originally equipped, position the fuel rail spacers.
100. Install the fuel rail with the fuel injectors and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
101. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
102. Install the EGR tube.
^ Tighten to 55 Nm (41 ft. lbs.).
103. 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.
Position the intake manifold and connect the positive crankcase ventilation hose.
104. 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.).
105. Connect the throttle position (TP) sensor electrical connector.
106. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
107. Connect the swirl control valve electrical connector.
108. Connect the idle air control (IAC) motor electrical connector.
109. Connect the temperature manifold absolute pressure (TMAP) electrical connector.
110. Connect the KS and attach the 2 wiring harness retainers.
111. Attach the 2 wiring harness retainers.
112. If removed, install the capacitor and bolt.
^ Tighten to 20 Nm (15 ft. lbs.).
113. 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 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
114. NOTICE: Early build with oil cooler shown, late build without oil cooler similar.
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.).
115. Connect the oil pressure sensor electrical connector.
116. 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.).
117. 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.).
118. If equipped, connect the oil cooler hoses.
119. Attach the 2 wiring harness retainers.
120. Install the engine vacuum tube.
^ Connect the engine vacuum tube.
^ Attach the 2 engine vacuum tube retainers.
121. 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.).
122. Install the coolant pump pulley and bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
123. If equipped, install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).
124. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).
125. Install the generator and bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
126. Position a new exhaust manifold gasket on the engine.
127. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown.
^ Stage 1: Tighten to 47 Nm (35 ft. lbs.).
^ Stage 2: Tighten to 47 Nm (35 ft. lbs.).
128. Install the heat shield and the 6 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
129. Install the 2 catalytic converter bracket bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
130. Connect the generator electrical connections and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).
131. Connect the CKP sensor electrical connector.
132. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
Vehicles with automatic transaxle
133. 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 (59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).
Vehicles with manual transaxle
134. 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 (59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).
135. Install the starter motor isolator.
136. NOTE: Use a clutch disc aligner (such as OTC© Clutch Alignment Tool Set 4258 or equivalent).
Using a suitable clutch disc aligner, position the clutch disc on the flywheel.
137. 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.