Steps 76 - End

76. CAUTION: The righthand camshaft sprocket bolt is a lefthand 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.





77. Install the RH camshaft tensioner.






78. 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.






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

Position the camshaft timing slots below centerline of camshaft and install the special tools on the rear of the LH cylinder head.





80. Install the special tool.





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





82. Install the LH camshaft tensioner.






83. NOTE: Lubricate the parts with clean engine oil prior to installing.

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





84. Install the gasket and the LH exhaust manifold and nuts.





85. Install the gasket and the RH exhaust manifold and nuts.






86. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.

Install the Knock Sensor (KS) and the bolt.





87. Install the oil level indicator tube and the bolt.





88. Install the thermostat housing.
1 Install the housing into the bypass hose.
2 Install the bolts.
3 Position the bypass hose clamp.





89. Install the gasket and the RH valve cover.





90. Install the gasket and the LH valve cover.





91. Install the Positive Crankcase Ventilation (PCV) valve and hoses.





92. Connect the PCV hose to the valve.





93. Install the fuel injection supply manifold.
1 Install the fuel injection supply manifold and the fuel injectors as an assembly.
2 Install the fuel supply tube to the fuel manifold.





94. Install the fuel supply tube lower bracket and bolt.





95. Install the fuel supply tube upper bracket and bolt.





96. Install and connect the Exhaust Gas Recirculation (EGR) valve tube to the exhaust manifold.





97. Install the fuel charging wiring.






98. NOTE: LH shown, RH similar.

Connect the six fuel injector electrical connectors.





99. Connect the fuel pressure sensor electrical and vacuum connectors.





100. Connect the coolant temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.





101. Connect new wiring harness retainers.





102. Connect the Crankshaft Position (CKP) sensor electrical connector.





103. Install the coolant tube bracket and bolts.





104. Attach the wiring harness retainer and install the heater tube bracket assembly.





105. Connect the heater hose and the PCV coolant hose.





106. Install the coolant hose.
107. Position the intake manifold close to the installed position.





108. Install the heated PCV fitting and the bolts.





109. Install the intake manifold and the bolts.





110. Connect and attach the electrical connector.





111. Connect the vacuum hoses.





112. Position the ignition coil and bracket assembly and install the upper bracket bolts.





113. Install the ignition coil bracket lower bolts.





114. Connect the ignition coil electrical connector.

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 dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires to the spark plugs.





116. Install the bolt and connect the radio ignition interference capacitor electrical connector.





117. Connect the Camshaft Position (CMP) sensor and the differential pressure feedback EGR system electrical connectors. Attach the wiring pin-type retainer.





118. Connect the EGR vacuum regulator solenoid valve electrical and vacuum connections.





119. Connect the following:
^ EGR valve vacuum hose.
^ EGR tube to the valve.





120. Connect the Idle Air Control (IAC) and the Throttle Position (TP) sensor electrical connector. Attach the TP sensor wiring routing clips.





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

122. NOTE: The lifting eyes should be installed on the exhaust manifold studs for number three and number four cylinders.

Install the Lifting Eyes.
123. Install the Spreader Bar to the Lifting Eyes.
124. Attach a floor crane to the Spreader Bar and remove the engine from the engine stand.






125. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface cleaner.

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





126. Using the special tool, install the crankshaft rear oil seal.






127. NOTE: Special bolts are used for flywheel installation. Do not use standard bolts.

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