Part 2

48. Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 20 Nm (14 ft. lbs.).
^ Stage 2: Tighten to 40 Nm (29 ft. lbs.).
^ Stage 3: Tighten to 50 Nm (36 ft. lbs.).





49. CAUTION: Each bolt must be loosened and the final tightening carried out prior to working on the next bolt in the sequence. Do not loosen all of the bolts at one time.

Carry out the following final tightening process on each bolt in the sequence shown.
^ Long bolts:
Loosen the long bolt and back out 3 turns.
Tighten the long bolt to 45 Nm (33 ft. lbs.).
Tighten the long bolt an additional 180 degrees.
Continue on to the next bolt in sequence.
^ Short bolts:
Loosen the short bolt and back out 3 turns.
Tighten the short bolt to 25 Nm (18 ft. lbs.).
Tighten the short bolt an additional 180 degrees.
Continue on to the next bolt in sequence.





50. Install the lower exhaust manifold studs on both cylinder heads.
^ Tighten to 8 Nm (71 inch lbs.).





51. NOTE: Lubricate the push rods with clean engine oil prior to installation. If reusing the push rods, make sure to install them in their original locations.

Install the 12 push rods.





52. NOTE: If reusing the rocker arms, make sure to install them in their original locations.

Install the rocker arms.
^ Position the rocker arms and pivots.
^ Hand-start the bolts.
^ Tighten the bolts in 2 stages.
Stage 1: Tighten to 5 Nm (44 inch lbs.).
Stage 2: Tighten to 32 Nm (24 ft. lbs.).





53. NOTE: Inspect the valve cover gaskets for damage. Install a new gasket, if necessary.

Install the valve covers.
1. Position the valve covers.
2. Install the bolts and tighten to 10 Nm (89 inch lbs.).
3. Install the stud bolts and tighten to 10 Nm (89 inch lbs.).

54. Using a new gasket, install the RH exhaust manifold. Loosely install the RH nuts.





55. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





56. Install the heat shield and the nuts.
^ Tighten to 10 Nm (89 inch lbs.).





57. Using a new gasket, install the LH exhaust manifold. Loosely install the LH nuts.





58. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





59. Refer to the illustration for intake manifold sealing components.





60. 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.





61. Position the intake manifold gaskets.





62. NOTE: The lower intake manifold must be installed within 4 minutes of applying the sealant.

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.





63. NOTE: Make sure the bolts are installed in the correct locations.

Install the 6 long bolts.





64. Install the 8 short bolts.





65. Tighten the lower intake manifold bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





66. Install new O-ring seals on the fuel injectors.





67. NOTE: Lubricate the O-ring seals with clean engine oil to aid installation.

Install the fuel injectors and retaining clips on the fuel supply manifold.





68. Install the fuel supply manifold, fuel injectors and fuel charging harness as an assembly and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





69. Using new gaskets, install the upper intake manifold and bolts.
^ Tighten the upper intake manifold bolts in 2 stages in the sequence shown.
Stage 1: Tighten to 6 Nm (53 inch lbs.).
Stage 2: Tighten to 10 Nm (89 inch lbs.).





70. Position the engine harness onto the engine and connect the engine harness-to-fuel charging harness electrical connector.





71. Position the vacuum harness onto the engine and connect the 2 vacuum harness connections.





72. Install the ignition coil and bolts.
^ Tighten to 6 Nm (53 inch lbs.).





73. Install the engine harness pin-type retainer and connect the ignition coil electrical connector.





74. NOTE: Do not tighten the EGR system module-to-manifold tube lower fitting.

Install the EGR system module-to-manifold tube.





75. Connect the following:
1. Idle air control (IAC) electrical connector
2. Throttle position (TP) sensor electrical connector
3. Exhaust gas recirculation (EGR) system module electrical connector
4. EGR system module vacuum connector
5. EGR system module-to-exhaust manifold tube upper fitting and tighten to 40 Nm (30 ft. lbs.)





76. Tighten the EGR system module-to-manifold tube lower fitting.
^ Tighten to 40 Nm (30 ft. lbs.).





77. Connect the cylinder head temperature (CHT) sensor electrical connector.





78. Install the 4 engine harness pin-type retainers.





79. NOTE: Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and the ignition coil.

Install and connect the spark plug wires and retainers as an assembly.





80. NOTE: Install a new oil level indicator tube O-ring seal.

Install the oil level indicator tube and the retaining nut.
^ Tighten to 10 Nm (89 inch lbs.).





81. Connect the quick disconnect crankcase vent hose to the intake manifold.





82. Connect the quick disconnect crankcase vent hose and connect the crankcase vent hose valve electrical connector.





83. Connect the intake manifold runner control (IMRC) electrical connector.





84. Connect the CMP sensor electrical connector.





85. Connect the oil pressure sensor electrical connector and install the engine harness pin-type retainer.





86. Install the RH engine mount bracket.
^ Tighten to 48 Nm (35 ft. lbs.).





87. Install the catalyst monitor sensor electrical connector bracket.
^ Tighten to 28 Nm (21 ft. lbs.).





88. Connect the CKP sensor electrical connectors.





89. Install the power steering pump bracket and mounting bolts.
1. Tighten to 25 Nm (18 ft. lbs.).
2. Tighten to 48 Nm (35 ft. lbs.).





90. Install the accessory drive belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





91. NOTE: Install a new coolant pump outlet tube O-ring seal and lubricate with clean engine coolant.

Install the coolant pump outlet tube.
^ Install the 2 bolts and tighten to 10 Nm (89 inch lbs.).
^ Connect the 3 coolant hoses.
Reposition the clamps.





92. Install the A/C compressor bracket and bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





93. Install the A/C compressor mounting bracket brace and generator mounting bracket as an assembly and install the bolts.
1. Tighten to 25 Nm (18 ft. lbs.).
2. Tighten to 47 Nm (35 ft. lbs.).





94. Install the coolant extension tube and bracket and bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





95. Install the generator and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





96. Connect the generator.
^ Install the B+ wire terminal and nut and tighten to 8 Nm (71 inch lbs.).
^ Connect the generator electrical connector.





97. Install the accessory drive idler pulley and bolt.
^ Tighten to 47 Nm (35 ft. lbs.).





98. Install the coolant pump pulley and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





99. NOTE: RH shown, LH similar.

Install the special tools.





100. Install the engine lifting equipment.
101. Remove the engine from the stand.





102. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.

Assemble the special tools and the crankshaft rear seal.





103. Install the special tools on the rear of the crankshaft.





104. Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303-561) contacts the engine block.





105. Install the flywheel and bolts.
^ Tighten to 80 Nm (59 ft. lbs.).