Operation CHARM: Car repair manuals for everyone.

Assembly (Part 3)

100. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness.
101. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).





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

103. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).





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





105. 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.).





106. Install the oil level indicator tube and bolt.





107. 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.





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

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





109. 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 injectors.





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

Install the fuel injectors.





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





112. Position the fuel supply tube and install the bolt.
^ Tighten to 6 Nm (53 inch lbs.).





113. NOTE: LH shown, RH similar.

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





114. Install the oil pressure switch.
^ Tighten to 13 Nm (10 ft. lbs.).





115. Position the battery cable and harness and attach the retainers.





116. Connect the oil pressure switch electrical connector. Position the battery cable and harness bracket and install the nut.
^ Tighten to 20 Nm (15 ft. lbs.).





117. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.
118. Position the engine wiring harness on the engine.





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





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





121. Connect the fuel rail pressure and temperature sensor and the camshaft position (CMP) sensor electrical connector.





122. Connect the crankshaft position (CKP) sensor electrical connectors and new wiring anchors.





123. NOTE: RH shown, LH similar.

Connect the 6 fuel injector electrical connectors and attach the wiring harness retainers.





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





125. Install the exhaust manifold-to-exhaust gas recirculation (EGR) system module tube.
^ Tighten to 34 Nm (25 ft. lbs.).





126. Connect the electronic throttle body (TB) and throttle position (TP) sensor electrical connectors. Attach the wiring harness bracket and install the nut.
^ Tighten to 9 Nm (80 inch lbs.).





127. Connect the exhaust gas recirculation (EGR) system module vacuum hose and electrical connector. Attach the wiring harness pin-type retainer.





128. Attach the wiring harness pin-type retainer and connect the KS electrical connector.





129. Connect the vacuum and positive crankcase ventilation (PCV) hoses to the intake manifold.





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





131. Connect the oil cooler hose. Position the oil cooler hose bracket and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





132. Position the ignition coil, bracket and spark plug wires as an assembly and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





133. NOTE: RH spark plug wires shown removed for clarity.

Attach the wiring harness retainer and connect the coil and radio interference capacitor electrical connectors.





134. 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.

Attach the LH spark plug wire retainers and connect the LH spark plug wires to the spark plugs.





135. 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.

Attach the RH spark plug wire retainers and connect the RH spark plug wires to the spark plugs.





136. Position the heater hose tube bracket and the hoses as an assembly and install the bolt.
^ Tighten to 23 Nm (17 ft. lbs.).





137. Connect the hose to the oil cooler.





138. Connect the heater hose to the thermostat housing.





139. 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.).





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





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





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





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





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





145. Install the left side lifting bracket.





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





147. 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.





148. Using the special tool, install the crankshaft rear oil seal.
149. Install the spacer plate.





150. 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.).