Steps 79-123

Engine



















Engine Induction System











Engine - Front End and Lower End











Engine - Flex Plate and Engine Lubrication











Engine - Upper End













Assembly

All engines


79. Install the new RH gasket into the valve cover and position on the cylinder head. Tighten the 11 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





80. Install the Knock Sensor (KS) and the nut.
- Tighten to 20 Nm (177 lb-in).





81. NOTE: Lubricate the O-ring seal with clean engine coolant.

Inspect the O-rings seals. Install new seals, if necessary.





82. Install the coolant bypass tube.





83. Install the ground strap on the rear of the RH cylinder head.

1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).

2. Install the ground strap.

3. Install the retaining nut and tighten to 10 Nm (89 lb-in).





84. Install the insert into the LH cylinder head.





85. NOTE: Align the gasket locator tabs to slots in cylinder head.

Install the new intake manifold gaskets, intake manifold and hand-tighten the 8 bolts at the locations shown.





86. Install the 8 ignition coils and tighten the 8 bolts (4 shown).
- Tighten to 6 Nm (53 lb-in).





87. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud bolt.





88. Install the thermostat.





89. Install the coolant outlet adapter and loosely install the 2 bolts.





90. Tighten the 9 bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





91. Tighten the stud bolt.
- Tighten to 25 Nm (18 lb-ft).





92. Tighten the 2 coolant outlet adapter bolts.
- Tighten to 25 Nm (18 lb-ft).





93. Connect the throttle control and throttle positioning sensor electrical connector.





94. Connect the EGR tube to the EGR valve.
- Tighten to 43 Nm (32 lb-ft).





95. Connect the EGR tube to the exhaust manifold.
- Tighten to 43 Nm (32 lb-ft).





96. Position the fuel charging wiring at 2 locations at the back of the intake manifold.

97. Install the generator and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





98. Install the generator mounting bracket and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





99. Attach the wire harness retainer and connect the generator electrical connector.





100. Position the vacuum harness and connect the vacuum hoses for the Evaporative Emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.





101. Connect the crankcase ventilation tube.





102. Install the intake manifold shield and 2 bolts.
- Tighten to 10 Nm (89 lb-in).





103. Connect the 8 fuel injector electrical connectors (4 shown).





104. Connect the 8 ignition coil electrical connectors (4 shown).





105. Connect the Camshaft Position (CMP) sensor electrical connector.





106. Connect the radio interference capacitor electrical connector.





107. Connect the KS electrical connector and install the harness retainer to the intake manifold.





108. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





109. Install the battery cables and the bolt.

110. Install the Engine Lifting Bracket to the RH cylinder head.





111. Install the Engine Lifting Bracket to the LH cylinder head.





112. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.





113. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer mating surface on the engine block.

Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the engine block.





114. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.





115. Tighten the 6 crankshaft rear seal retainer plate bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





116. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply the sealant at the rear oil seal retainer to cylinder block sealing surface.





117. Apply sealant at the front cover-to-cylinder block sealing surface.





118. Position the new oil pan gasket, the oil pan and the loosely install the 16 bolts.





119. Tighten the 16 bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Rotate an additional 60 degrees.





120. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear oil seal.





121. Using the Crankshaft Rear Oil Seal Installer and Crankshaft Rear Oil Slinger Installer, install the crankshaft oil slinger.





122. Install the engine/transmission spacer plate.





123. Position the flexplate and install the 6 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).