Part 2
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ENGINE ASSEMBLY - 2.3L
Part 2
Continued From Part 1 Part 1
1. Remove the holding fixture SST and the crankshaft pulley/holding tool SST.
1. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
1. Remove the crankshaft timing peg SST.
1. Remove the camshaft alignment plate SST.
2.
NOTE:Only turn the engine in the normal direction of rotation.Turn the engine two complete revolutions.
3.
NOTE:Only turn the engine in the normal direction of rotation.Turn the engine until the No. 1 piston is at top dead center (TDC).
1. Install the crankshaft timing peg SST.
1.
CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, correct the engine timing.
1. Using the camshaft alignment plate SST, check the position of the camshafts.
- If it is not possible to install the special tool, correct the engine timing.
1. Remove the camshaft alignment plate SST.
1. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
1. Remove the crankshaft timing peg SST.
1. Install the timing peg plug.
1.
NOTE:The crankshaft position (CKP) sensor alignment tool is supplied with the new sensor and is not available separately.Using the CKP sensor alignment tool, install a new CKP sensor. The CKP sensor alignment tool must engage a tooth of the vibration damper.
2. Clean the valve cover gasket surface with metal surface cleaner.
1. Apply silicone gasket and sealant to the locations shown.
1.
NOTE:The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.Install the valve cover.
1. Install the camshaft position (CMP) sensor, cylinder head temperature (CHT) sensor and spark plugs.
1.
NOTE:Clean the water pump gasket surface with metal surface cleaner.
NOTE:Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly.
Install the coolant pump.
1. Install the coolant pump pulley.
1. Install the fuel injection supply manifold and the ground strap.
1. Install the left motor mount.
1.
NOTE:The knock sensor (KS) must not touch the engine vent cover.Install the engine vent cover and the KS.
NOTE:Clean the thermostat housing gasket surface with metal surface cleaner.Install a new gasket and the thermostat housing.
1. Install the ignition coil.
2.
NOTE:Apply silicone dielectric compound to the inside of the spark plug boots.Connect the spark plug wires to the spark plugs.
1. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
1. Connect the ignition coil and the CHT sensor electrical connectors.
1. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.
1. Install the intake manifold.
1. Secure the fuel hose clip to the intake manifold.
1. Install the exhaust gas recirculation (EGR) tube.
- Install the EGR tube bracket to the intake manifold.Tightening Torque:10 Nm {89 in-lb}
- Connect the EGR tube to the cylinder head.Tightening Torque:55 Nm {41 in-lb}
1. Connect the EGR tube to the intake manifold.
2. Attach the engine wiring harness pin-type retainers to the intake manifold.
1. Connect the CMP sensor electrical connector and the PCV hose.
1. Install the engine wiring harness connector bracket and connect the KS electrical connector.Tightening Torque:10 Nm {89in-lb}
1. Connect the CKP sensor and wiring pin-type retainers.
1. Connect the manifold absolute pressure (MAP) sensor, throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
1. Install the power steering pump assembly.
1.
NOTE:Clean the EGR valve gasket surface with metal surface cleaner.Install the EGR valve. Tightening Torque:20 Nm {15 ft-lb}
1 Using a new gasket, position the EGR valve and install the 2 bolts.
2 Connect the coolant hose.
3 Connect the electrical connector.
2.
NOTE:Clean the rear coolant outlet pipe gasket surface with metal surface cleaner.Install a new gasket and the rear coolant outlet pipe.
a. Tighten the bolts.Tightening Torque:10 Nm {89 in-lb}
b. Connect the coolant hose.
c. Connect the engine coolant temperature sender unit electrical connector.
1. Install the block heater, if equipped.
1. Install the gasket and the exhaust manifold.
1. Install the coolant tube assembly.
1. Connect the coolant hose to the thermostat and coolant hose to the positive crankcase ventilation (PCV) fitting on the intake manifold.
1. Install the right motor mount.
1. Position the front end accessory drive (FEAD) mounting bracket and install the bolts in the sequence shown in two stages.
- Stage 1: Install finger tight.
- Stage 2: Tighten to 47 Nm (35 lb-ft).
1. Install the A/C compressor.
1.
NOTE:Lubricate the O-ring seal with engine coolant.Install the front coolant outlet pipe.
1.
NOTE:Lubricate the O-ring seal with clean engine oil.Install the engine oil level indicator tube and the bolts.
- Install the oil level indicator.
1. Install the accessory drive belt.
2. Using the spreader bar and the floor crane, remove the engine from the engine stand.
3. Install the flywheel or the flexplate and the bolts.
1. Install the flywheel locking tool SST.
1. Tighten the bolts in the sequence shown in three 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).
Vehicles with manual transmission
1. Lubricate the transmission input shaft pilot bearing with front axle grease.
1. Adjust the clutch pressure plate.
a. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
b. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
c. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
1. Using the clutch disc aligner SST, position the clutch disc on the flywheel.
1.
NOTE:If reusing the clutch pressure plate and flywheel, align the marks made during removal.Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
- Remove the clutch disc aligner SST.