Part 3
Engine
Assembly (Steps 86-122)
86. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plugs.
Install a new cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 lb-ft).
^ Tighten the spark plugs to 12 Nm (9 lb-ft).
87. 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 8 Nm (71 lb-inch).
88. Install the 3 engine cover studs.
89. If equipped, install the block heater.
^ Tighten to 21 Nm (15 lb-ft).
90. Install the coolant hoses.
91. NOTE: Clean the gasket mating surfaces with metal surface cleaner.
Install the oil filter adapter with a new gasket.
^ Tighten to 25 Nm (18 lb-ft).
92. 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 lb-inch).
^ Tighten the KS to 20 Nm (15 lb-ft).
93. Install the coolant hose.
94. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
Install the thermostat housing.
^ Tighten to 10 Nm (89 lb-inch).
95. Install the coolant hose.
96. 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 lb-inch).
97. Install the coolant pump pulley and bolts.
^ Tighten to 20 Nm (15 lb-ft).
98. Position the engine control wiring harness on the engine and connect the EGR valve electrical connector.
99. Connect the CHT sensor and install the rubber boot.
100. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
101. Install the fuel rail with the fuel injectors and the 2 stud bolts.
^ Tighten to 23 Nm (17 lb-ft).
102. Install the radio capacitor and the nut.
^ Tighten to 10 Nm (89 lb-inch).
103. Install the EGR tube.
^ Tighten to 55 Nm (41 lb-ft).
104. Position the intake manifold and connect the PCV hose.
105. NOTE: Inspect and install new intake manifold gaskets, if necessary.
Install the intake manifold gasket and intake manifold and 8 bolts.
^ Tighten to 18 Nm (13 lb-ft).
106. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
107. Attach all the wire harness pin-type retainers to the intake manifold.
108. Connect the 4 fuel injector electrical connectors and the radio capacitor electrical connector.
109. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
110. Connect the manifold absolute pressure (MAP) sensor electrical connector.
111. Connect the engine oil pressure (EOP) switch electrical connector.
112. Connect the evaporative emissions (EVAP) tube quick connect coupling to the intake manifold.
113. Connect the lower coolant hose to the throttle body.
114. Connect the upper coolant hose to the throttle body.
115. Connect the throttle body electrical connector.
116. Install the oil level indicator tube and the 2 bolts.
^ Tighten the lower bolt to 47 Nm (35 lb-ft).
^ Tighten the upper bolt to 10 Nm (89 lb-inch).
117. Install the accessory drive belt tensioner.
^ Tighten to 25 Nm (18 lb-ft).
118. Attach the engine wiring harness pin-type retainer.
119. Install the engine wiring harness connector bracket.
^ Tighten to 15 Nm (11 lb-ft).
120. Connect the CKP sensor electrical connector.
121. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
122. NOTE: Special bolts are used for installation. Do not use standard bolts.
Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
^ Stage 1: Tighten to 50 Nm (37 lb-ft).
^ Stage 2: Tighten to 80 Nm (59 lb-ft).
^ Stage 3: Tighten to 112 Nm (83 lb-ft).
