Steps 51 - 92
51. Install the Dower steering pump bracket.
52. Using the special tool, install the power steering pump pulley.
53. Install the A/C compressor bracket and the bolts.
54. Install the accessory drive belt.
55. Refer to the illustration for intake manifold sealing components.
56. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Install the lower intake manifold front and rear end seals.
1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals.
57. Install the intake manifold gaskets.
58. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Position the lower intake manifold.
1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.
2. Position the lower intake manifold.
59. Install the lower intake manifold bolts.
- Install the six long bolts.
- Install the eight short bolts.
60. Tighten the bolts in two stages in the sequence shown.
1. Stage 1: Tighten to 5 Nm (44 inch lbs.).
2. Stage 2: Tighten to 10 Nm (89 inch lbs.).
61. Install the heater water outlet tube.
62. Install the stud bolt.
63. Position the engine wire harness.
64. Connect the crankshaft position sensor electrical connector.
65. Install the pin-type retainer.
66. Connect the engine oil pressure sender electrical connector.
67. Connect the camshaft position (CMP) sensor electrical connector.
68. Connect the cylinder head temperature (CHT) sensor.
69. Install the fuel injectors and the fuel injection supply manifold as an assembly.
70. Install a new upper intake manifold gasket.
71. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.
Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Rotate an additional 90 degrees.
72. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connections.
73. Connect the differential pressure feedback EGR system electrical and vacuum connections.
74. Connect the vacuum hoses.
75. Install the positive crankcase ventilation (PCV) tube.
76. Connect the ignition coil and the radio interference capacitor electrical connectors.
77. Position and connect the LH spark plug wires.
78. Position and connect the RH spark plug wires.
79. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
80. Install the RH exhaust manifold.
- Install a new exhaust manifold gasket.
- Install the exhaust manifold.
- Tighten the nuts in the sequence shown.
81. Install the exhaust gas recirculation (EGR) tube.
82. Connect the EGR valve nut.
83. Using a new gasket, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
84. NOTE: Install a new O-ring seal.
Install the oil level indicator and tube and retaining bolt.
85. Install the special tool.
86. Install the special tool.
87. Install the RH engine support insulator.
88. Install the LH engine support insulator.
89. Remove the engine from the stand.
90. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
91. Install the special tools on the rear of the crankshaft.
92. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the engine block.