Part 2

50. Clean the valve cover gasket surface with metal surface cleaner.





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





52. 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.





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





54. NOTE: Clean the water pump gasket surface with metal surface cleaner.

NOTE: Lubricate the water pump O-ring seal with clean engine coolant prior to assembly.

Install the coolant pump.





55. Install the coolant pump pulley.





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





57. Install the left motor mount.





58. NOTE: The knock sensor must not touch the engine vent cover.

Install the engine vent cover and the knock sensor (KS).





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

Install a new gasket and the thermostat housing.





60. Install the ignition coil.

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

Connect the spark plug wires to the spark plugs.





62. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.





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





64. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.





65. Install the intake manifold.





66. Secure the fuel hose clip to the intake manifold.





67. Install the exhaust gas recirculation (EGR) tube.
^ Install the EGR tube bracket to the intake manifold.
^ Connect the EGR tube to the cylinder head.





68. Connect the EGR tube to the intake manifold.
69. Attach the engine wiring harness pin-type retainers to the intake manifold.





70. Connect the CMP sensor electrical connector and the PCV hose.





71. Install the engine wiring harness connector bracket and connect the knock sensor electrical connector.





72. Connect the CKP sensor and wiring pin-type retainers.





73. Connect the following electrical connectors:
^ Manifold absolute pressure (MAP) sensor.
^ Throttle position (TP) sensor.
^ Idle air control (IAC) valve.





74. Install the power steering pump assembly.





75. NOTE: Clean the EGR valve gasket surface with metal surface cleaner.

Install a new gasket and the EGR valve. Connect the EGR electrical connector and coolant hose.





76. NOTE: Clean the rear coolant outlet pipe gasket surface with metal surface cleaner.

Install a new gasket and the rear coolant outlet pipe.
1. Tighten the bolts.
2. Connect the coolant hose.
3. Connect the engine coolant temperature sender unit electrical connector.





77. Install the block heater, if so equipped.





78. Install the gasket and the exhaust manifold.





79. Install the coolant tube assembly.





80. Connect the following:
^ Coolant hose to the thermostat.
^ Coolant hose to the PCV fitting on the intake manifold.





81. Install the right motor mount.





82. Position the FEAD bracket and install the bolts in the sequence shown in two stages.
^ Stage 1: Install the bolts finger tight.
^ Stage 2: Tighten the bolts to 47 Nm (35 ft. lbs.).





83. Install the A/C compressor.





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

Install the front coolant outlet pipe.





85. NOTE: Lubricate the O-ring seal with clean engine oil.

Install the engine oil level indicator tube and the bolt.
^ Install the oil level indicator.





86. Install the accessory drive belt.
87. Using the Spreader Bar and the Floor Crane, remove the engine from the Engine Stand.
88. Install the flywheel or the flexplate and the bolts.





89. Install the special tool.





90. 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 with manual transmission





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





92. 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.





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





94. 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.