Part 2

Engine

Assembly

65. NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, install a new crankshaft front oil seal.





66. NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





67. CAUTION: Only hand-tighten the 6 mm (0.23 inch) bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.





68. CAUTION: The crankshaft must remain in the top dead center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 lb-ft).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).





69. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





70. Remove the special tool.





71. Remove the special tool.





72. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.
73. Install the special tool.





74. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the special tool.





75. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, the engine valve timing must be corrected.





76. Install the special tool to check the position of the camshafts.
^ If it is not possible to install the special tool, the engine valve timing must be corrected.





77. Remove the special tool.





78. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.





79. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 Nm (62 lb-inch).





80. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





81. Remove the special tool.





82. Install the engine plug bolt.
^ Tighten to 20 Nm (15 lb-ft).





83. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the valve cover gasket surface with metal surface prep.

84. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.

Apply silicone gasket and sealant to the locations shown.





85. Install the valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 lb-inch).





86. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.

Install the oil level indicator.





87. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 coil-on-plug assemblies 4 bolts.
^ Tighten to 8 Nm (71 lb-inch).





88. 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.





89. Install the fuel rail and injector assembly and the 2 bolts.
^ Tighten to 23 Nm (17 lb-ft).





90. NOTE: Typical wiring harness retainers shown.

Position the wiring harness on the engine and attach the wiring harness retainers.





91. Connect the 4 fuel injector electrical connectors.





92. Install the fuel supply rail insulator and attach the 2 pin-type harness retainers.





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





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





95. Connect the VCT solenoid electrical connector.





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





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





98. NOTE: Lubricate the oil filter seal (spin on filter type) or oil filter cup O-ring seal (replaceable filter element type) with clean engine oil.

Install a new engine oil filter.
^ Tighten the oil filter (spin on filter type) to 18 Nm (13 lb-ft).
^ Tighten the oil filter cup (replaceable filter element type) to 33 Nm (24 lb-ft).
73. Using a new gasket, install the crankcase vent oil separator and the bolts.
^ Tighten to 10 Nm (89 lb-inch).





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

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





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





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





102. 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 lb-inch).





103. Install the EGR tube.
^ Tighten to 55 Nm (41 lb-ft).





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





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





106. Connect the electronic throttle body (TB) electrical connector.





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





108. Connect the 2 swirl control valve electrical connectors.





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





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





111. Connect the engine oil pressure (EOP) switch electrical connector.





112. Connect the EGR coolant hose and electrical connector.





113. Connect the coolant temperature sender electrical connector.





114. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 35 Nm (26 lb-ft).





115. If equipped, install the block heater.
^ Tighten to 21 Nm (15 lb-ft).





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





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

118. 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 lb-ft).
^ Stage 2: Tighten to 55 Nm (41 lb-ft).





119. Install the 2 catalytic converter bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).





120. NOTE: Vehicles equipped with AIR did not require removal of the catalytic converter heat shield.

Install the catalytic converter heat shield and the 6 screws.
^ Tighten to 10 Nm (89 lb-inch).





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





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





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





124. NOTE: Vehicles equipped with AIR have 2 catalyst monitor sensors.

Connect the catalyst monitor sensor electrical connector(s).





Vehicles with secondary air injection (AIR)

125. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).





126. Connect the AIR valve electrical connector.





127. Connect the AIR valve vacuum supply tube to the intake manifold.





128. Connect the AIR hose to the catalytic converter.





All vehicles

129. Install the generator, bolt and 2 stud bolts.
^ Tighten to 47 Nm (35 lb-ft).





130. Connect the pin-type retainer, generator electrical connections and install the nut.
^ Tighten to 6 Nm (53 lb-inch).
^ Install the rubber boot.





131. Install the generator splash shield and the 2 nuts.
^ Tighten to 25 Nm (18 lb-ft).





132. Connect the CKP sensor electrical connector and harness pin-type retainer.





133. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 lb-ft).





134. NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.

Install the new O-ring, coolant pump and the 3 bolts.
^ Tighten to 10 Nm (89 lb-inch).