Part 3

Engine

Assembly





94. Connect the cylinder head temperature (CHT) sensor electrical connector and install the boot.





95. Connect the 4 coil-on-plug electrical connectors.





96. Connect the VCT solenoid electrical connector.





97. Connect the camshaft position (CMP) sensor electrical connector.





98. Install a new gasket, the oil filter adapter and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





99. Using a new gasket, install the crankcase vent oil separator and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).

100. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.





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





101. Position the bypass hose on the engine and connect the bypass hose to the coolant outlet.





102. Connect the bypass hose to the cylinder block nipple.

103. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.





Install the thermostat housing and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





104. Install the EGR tube.
^ Tighten to 55 Nm (41 ft. lbs.).





105. Position the intake manifold and connect the positive crankcase ventilation hose.





106. Install new gaskets, the intake manifold and the 8 bolts.
^ Tighten the bolts to 18 Nm (13 ft. lbs.).





107. Connect the electronic throttle body electrical connector.





108. Attach the 2 wiring harness pin-type retainers to the intake manifold.





109. Connect the 2 swirl control valve electrical connectors.





110. Connect the intake manifold runner control (IMRC) actuator electrical connector.





111. Connect the temperature manifold actual pressure (MAP) sensor electrical connector.





112. Connect the oil pressure sender electrical connector.





113. Connect the exhaust gas recirculation (EGR) coolant hose and electrical connector.





114. Connect the coolant temperature sender electrical connector.





115. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 35 Nm (26 ft. lbs.).





116. If equipped, install the block heater.
^ Tighten to 21 Nm (15 ft. lbs.).





117. If equipped, connect the block heater electrical connector.

118. Install 7 new catalytic converter studs in the cylinder head.
^ Tighten to 17 Nm (13 ft. lbs.).

119. 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.





Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs.).
^ Stage 2: Tighten to 55 Nm (41 ft. lbs.).





120. Install the 2 catalytic converter bracket bolts.
^ Tighten to 20 Nm (15 ft. lbs.).

121. NOTE: Vehicles equipped with AIR did not require removal of the heat shield.





Install the heat shield and the 6 screws.
^ Tighten to 10 Nm (89 inch lbs.).





122. Attach the wiring harness retainer to the valve cover stud.





123. Attach the wiring harness bracket to the valve cover stud.





124. Connect the heated oxygen sensor (HO2S) electrical connector.