Part 4
Engine
Assembly (Steps 112-146)
112. Position the engine wiring harness retainer and install the bolt.
^ Tighten to 47 Nm (35 lb-ft).
113. Connect the engine coolant temperature (ECT) sensor electrical connector.
114. Connect the fuel rail pressure and temperature sensor and the camshaft position (CMP) sensor electrical connector.
115. Connect the crankshaft position (CKP) sensor electrical connectors and new wiring anchors.
116. NOTE: RH shown, LH similar.
Connect the 6 fuel injector electrical connectors and attach the wiring harness retainers.
117. Install the gaskets, the intake manifold and the bolts.
^ Tighten to 11 Nm (8 lb-ft).
118. Install the exhaust manifold-to-EGR system module tube.
^ Tighten to 34 Nm (25 lb-ft).
119. 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 lb-in).
120. Connect the EGR system module vacuum hose and electrical connector. Attach the wiring harness pin-type retainer.
121. Attach the wiring harness pin-type retainer and connect the KS electrical connector.
122. Connect the vacuum and PCV hoses to the intake manifold.
123. Install the oil cooler and hose.
^ Tighten to 57 Nm (42 lb-ft).
124. Connect the oil cooler hose. Position the oil cooler hose bracket and install the bolt.
^ Tighten to 25 Nm (18 lb-ft).
125. Position the ignition coil, bracket and spark plug wires as an assembly and install the bolts.
^ Tighten to 10 Nm (89 lb-in).
126. NOTE: RH spark plug wires shown removed for clarity.
Attach the wiring harness retainer and connect the coil and radio interference capacitor electrical connectors.
127. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold, or the spark plug wires may be damaged.
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.
128. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold, or the spark plug wires may be damaged.
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.
129. Position the heater hose tube bracket and the hoses as an assembly and install the bolt.
^ Tighten to 23 Nm (17 lb-ft).
130. Connect the hose to the oil cooler.
131. Connect the heater hose to the thermostat housing.
132. Install the generator mounting bracket.
1 Install the generator mounting bracket bolts.
^ Tighten to 42 Nm (31 lb-ft).
2 Install the drive belt tensioner and bolt.
^ Tighten to 47 Nm (35 lb-ft).
133. Connect the generator electrical connections and the wire harness retainer.
^ Tighten to 9 Nm (80 lb-in).
134. Install the accessory bracket and the bolts.
^ Tighten to 42 Nm (31 lb-ft).
135. Connect the A/C compressor electrical connector and wire harness retainer.
136. Install the bolt.
^ Tighten to 10 Nm (89 lb-in).
137. Install the right side lifting bracket.
^ Tighten to 37 Nm (27 lb-ft).
138. Install the left side lifting bracket.
139. Using the special tool and a floor crane, remove the engine from the engine stand.
140. 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.
141. Install the special tools.
142. Position the crankshaft rear seal.
143. Using the special tool, install the crankshaft rear oil seal.
144. Install the spacer plate.
145. Install the flexplate-to-crankshaft spacer.
146. NOTE: Special bolts are used for flexplate installation. Do not use standard bolts.
Install the flexplate.
^ Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 13 Nm (10 lb-ft).
^ Stage 2: Tighten to 50 Nm (37 lb-ft).
^ Stage 3: Tighten an additional 90 degrees.
