Part 2

Engine Continued





36. Remove the special tools.
37. Remove the M6 bolt.





38. Remove the special tool.





39. Remove the special tool from the camshafts.





40. Install the side plug.
41. Clean the valve cover gasket surface with metal surface cleaner.





42. Apply silicone gasket and sealant to the locations shown.

43. 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.
^ Tighten the bolts in the sequence shown.





44. Install the following:
^ Camshaft position (CMP) sensor.
^ Cylinder head temperature (CHT) sensor.
^ Spark plugs.

45. NOTE: Apply dielectric compound to the inside of the coil boots. Install the ignition coils.

^ Tighten the bolts to 10 Nm (89 inch lbs.).

46. NOTE: Clean the coolant pump gasket surface with metal surface cleaner.

NOTE: Lubricate the coolant pump O-ring seal with MERPOL (R) prior to assembly.





Install the coolant pump.





47. Install the coolant pump pulley.





48. Install the fuel injection supply manifold and the ground strap.

49. NOTE: The knock sensor (KS) must not touch the engine vent cover.





Install the engine vent cover and the KS.

50. NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.





Install a new gasket and the thermostat housing.





51. Install the bypass hose and the clamp.





52. Connect the ignition coil and the CHT sensor electrical connectors.





53. Reposition the CHT sensor boot.





54. Connect the fuel injector connector and the wiring harness pin-type retainers.





55. Install the intake manifold assembly.





56. Secure the pin-type retainers to the intake manifold.





57. Install the positive crankcase ventilation (PCV) hose.





58. Connect the crankshaft position (CKP) sensor electrical connector and the wiring harness pin-type retainers.





59. Connect the swirl control valve monitor electrical connector and the hose.





60. Connect the idle air control (IAC) motor electrical connector.





61. Connect the throttle position (TP) sensor electrical connector.





62. Install the exhaust gas recirculation (EGR) valve.
1 Install the EGR valve and bolts.
2 Connect the EGR valve electrical connector.





63. Install the block heater, if equipped.





64. Connect the knock sensor (KS) electrical connector.





65. Connect the heater hose to the thermostat housing.





66. Connect the coolant hose to the EGR valve.





67. Install the generator.





68. Install the coolant bypass.
1 Install the bolts.
2 Install the hose.





69. Install the oil level indicator tube.
1 Install the oil level indicator tube.
2 Install the bolts.
3 Install the oil level indicator.





70. Install the accessory drive belt.
71. Using the heavy duty floor crane and the spreader bar, remove the engine from the stand.





72. Install the flywheel or the flexplate and the bolts. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the bolts to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten the bolts to 80 Nm (59 ft. lbs.).
^ Stage 3: Tighten the bolts to 112 Nm (83 ft. lbs.).

Vehicles equipped with a manual transmission





73. Lubricate the transmission input shaft pilot bearing with front axle grease.





74. Adjust the clutch pressure plate.
1 Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3 Release the pressure on the fingers. The adjusting ring will stay in the reset position.





75. Using the special tool, position the clutch disc on the flywheel.

76. 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.