Part 3
EngineAssembly (Steps 91-135)
91. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
92. Install a new gasket, the RH exhaust manifold and new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).
93. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.
Install the knock sensor (KS) and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
94. Install the oil level indicator tube and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
95. Install the thermostat housing.
1. Position the housing into the bypass hose.
2. Install the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
3. Position the bypass hose clamp.
96. Install the gasket and the RH valve cover.
97. Install the gasket and the LH valve cover.
98. Install the positive crankcase ventilation (PCV) valve and hoses.
99. Connect the PCV hose to the valve.
100. Install the fuel rail and the fuel injectors as an assembly. Install the fuel rail bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
101. Install the fuel supply tube lower bracket and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
102. Install the fuel supply tube upper bracket and bolt.
103. Install the exhaust gas recirculation (EGR) valve tube to the exhaust manifold.
^ Tighten to 34 Nm (25 ft. lbs.).
104. Install the fuel charging wiring.
105. NOTE: LH shown, RH similar.
Connect the 6 fuel injector electrical connectors.
106. Connect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
107. Connect new wiring harness retainers.
108. Connect the crankshaft position (CKP) sensor electrical connector.
109. Install the coolant tube bracket and bolts.
^ Tighten the large bolt to 28 Nm (21 ft. lbs.) and the small bolt to 23 Nm (17 ft. lbs.).
110. Attach the wiring harness retainer and install the heater tube bracket assembly.
111. Connect the heater hose and the PCV coolant hose.
112. Install the coolant hose.
113. Position the intake manifold close to the installed position.
114. Install the heated PCV fitting and the bolts.
^ Tighten to 8 Nm (71 inch lbs.).
115. Install the intake manifold and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
116. Connect and attach the electrical connector.
117. Connect the vacuum hoses.
118. Position the ignition coil and bracket assembly and Install the upper bracket bolts.
^ Tighten to 8 Nm (71 inch lbs.).
119. Install the ignition coil bracket lower bolts.
^ Tighten the large bolt to 28 Nm (21 ft. lbs.) and the small bolt to 23 Nm (17 ft. lbs.).
120. Connect the ignition coil electrical connector.
121. 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.
122. Install the bolt and connect the radio ignition interference capacitor electrical connector.
^ Tighten to 6 Nm (53 inch lbs.).
123. Connect the camshaft position (CMP) sensor and the differential pressure feedback EGR system electrical connectors. Attach the wiring pin-type retainer.
124. Connect the EGR vacuum regulator solenoid valve electrical and vacuum connections.
125. Connect the EGR valve vacuum hose and EGR tube.
^ Tighten to 34 Nm (25 ft. lbs.).
126. Connect the idle air control (IAC) and the throttle position (TP) sensor electrical connector. Attach the TP sensor wiring routing clips.
127. Install the generator mounting bracket.
1. Install the generator mounting bracket and bolts.
^ Tighten to 42 Nm (31 ft. lbs.).
2. Install the drive belt tensioner and bolt.
^ Tighten to 47 Nm (35 ft. lbs.).
128. NOTE: The lifting brackets should be installed on the exhaust manifold studs for No. 3 and No. 4 cylinders.
Install the Engine Lifting Brackets.
129. Install the Spreader Bar to the Engine Lifting Brackets.
130. Attach a floor crane to the Spreader Bar and remove the engine from the engine stand.
131. 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 seal with clean engine oil and install it on the special tool.
132. Install the special tools.
133. Position the crankshaft rear seal and the special tool.
134. Using the special tool, install the crankshaft rear seal.
135. NOTE: Special bolts are used for flywheel installation. Do not use standard bolts.
Install the flywheel.
^ Tighten the bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 13 Nm (10 ft. lbs.).
^ Stage 2: Tighten to 71 Nm (52 ft. lbs.).