Part 2

Engine Continued





69. CAUTION: A new bolt must be used each time it is removed.

NOTE: Late build pulley shown, early build pulley similar.

Using the special tool, tighten the bolt in two stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Rotate an additional 90 degrees.





70. Install the coolant pump pulley and the bolts.





71. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install and hand-tighten the RH rear camshaft bolt.





72. Install the bolt.





73. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install and hand-tighten the LH front camshaft bolt.





74. Install the bolt.
75. Turn the crankshaft one revolution clockwise.





76. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).

NOTE: Late build pulley shown, early build pulley similar.

Install the special tool.





77. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.





78. NOTE: Leave the top two special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.





79. Install the special tool.





80. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Tighten the bolts.
1. Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2. Tighten the camshaft bolt.





81. Remove the special tool and install the RH camshaft tensioner.





82. NOTE: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.





83. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the rear of the LH cylinder head.





84. Install the special tool.





85. Tighten the bolts.
1. Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2. Tighten the camshaft bolt.





86. Install the LH camshaft tensioner.





87. Rotate the crankshaft until the cam lobe is in the up position.





88. NOTE: Lubricate the parts with clean engine oil.

Using the special tool, install the roller followers in their original position.





89. Install a new gasket and the RH exhaust manifold and nuts.





90. Install a new gasket and the LH exhaust manifold and nuts.





91. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces. Install the knock sensor (KS).





92. Install the oil level indicator tube and bolt.





93. Install the thermostat housing.
1. Install the thermostat housing and bypass hose onto the coolant pump.
2. Install the bolts.
3. Position the bypass hose clamp.





94. NOTE: RH valve cover shown, LH similar.

Install the valve covers and tighten the bolts.





95. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Do not reuse the O-ring seals.

Install new O-ring seals on each of the fuel injectors.





96. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.

Install the fuel injectors.





97. Install the fuel injection supply manifold and the belt





98. NOTE: LH shown, RH similar.

Install the LH and RH insulator brackets and the bolts.





99. Install the oil pressure switch.





100. Install the battery cable and connect the oil pressure switch electrical connector.





101. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor and fuel pulse damper vacuum hose fittings.





102. Position the engine wiring harness on the engine.





103. Position the engine wiring harness retainer and install the bolts.





104. Connect the crankshaft position (CKP) sensor electrical connectors and wiring anchors.





105. NOTE: RH shown, LH similar.

Connect the six fuel injector electrical connectors.





106. Install the gaskets, intake manifold and the bolts.





107. Connect the exhaust gas recirculation (EGR) system module vacuum hose and electrical connector.
^ Attach the wiring harness pin-type retainer.





108. Connect the electronic throttle body and throttle position (TP) sensor electrical connectors.





109. Attach the wiring harness pin-type retainer and connect the knock sensor electrical connector.





110. Connect the vacuum harness.





111. Position the fuel tube.

Engines equipped with an oil cooler





112. Install the oil cooler and hoses.





113. Position the oil cooler hose brackets and install the bolts.

All engines





114. Position the ignition coil and bracket assembly and install the bolts.





115. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires.





116. Connect these electrical connectors:
^ Camshaft position (CMP) sensor.
^ Ignition coil.
^ Engine coolant temperature (ECT) sensor.
^ Ignition radio interference capacitor.
^ Fuel pressure and temperature sensor.





117. Install the generator mounting bracket.
1. Install the generator mounting bracket bolts.
2. Install the drive belt tensioner and bolt.





118. Connect the generator electrical connections and the wire harness retainer.





119. Install the accessory bracket and tighten the bolts.





120. Connect the A/C compressor electrical connector and wire harness retainer.





121. Install the bolts.





122. Install the A/C hose.





123. Install the right side lifting bracket.





124. Install the left side lifting bracket.





125. Using the special tool and a floor crane, remove the engine from the engine stand.





126. NOTE: Be sure that the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use an extra-fine emery cloth or an extra-fine steel wool with metal surface cleaner.

Lubricate the crankshaft rear oil seal with engine oil and install on the special tool.





127. Using the special tool, install the crankshaft rear oil seal.
128. Install the spacer plate.





129. NOTE: Special bolts are used for flexplate installation. Do not use standard bolts.

Install the flexplate.
^ Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 13 Nm (10 ft. lbs.).
^ Stage 2: Tighten the bolts to 71 Nm (52 ft. lbs.).