Part 2
EngineAssembly (Steps 47-92)
47. Install new VCT housing seals.
48. CAUTION: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.
Install the LH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
49. CAUTION: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.
Install the RH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
50. Install the special tools.
51. NOTE: If the engine front cover, engine mount bracket and bolts 7, 8, 17, 18, 19, 20, 23, 24 and 25 are not installed and tightened within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 inch) bead of silicone gasket and sealant to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket and sealant to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover.
52. Install the engine front cover and bolts 7, 8, 17, 18, 19 and 20.
^ Tighten in the sequence to 10 Nm (89 inch lbs).
53. Install the engine mount bracket and the 3 bolts.
^ Tighten in the sequence shown to 15 Nm (11 ft. lbs).
54. Tighten the bolts in this sequence.
^ Tighten bolts 7, 8, 17, 18, 19 and 20 to 24 Nm (18 ft. lbs).
^ Tighten bolts 23, 24 and 25 to 75 Nm (55 ft. lbs).
55. Remove the special tools (alignment pins).
56. NOTE: The remainder of the engine front cover bolts (1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22) must be installed and tightened within 60 minutes of the initial sealant application.
Install bolts 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, 16, 21 and 22 and tighten in the sequence shown in 2 stages:
^ Stage 1: Tighten to 10 Nm (89 inch lbs).
^ Stage 2: Tighten to 24 Nm (18 ft. lbs).
57. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 ft. lbs).
58. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the special tools, install a new crankshaft front seal.
59. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the special tools, install the crankshaft pulley.
60. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees.
61. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
NOTE: Spark plug tube seal installation shown, VCT seal installation similar.
Using the special tools, install new VCT solenoid and/or spark plug tube seals.
62. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a 8 mm (0.31 inch) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.
63. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
64. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a 8 mm (0.31 inch) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.
65. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
66. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 inch lbs).
67. NOTE: Engine without oil cooler shown, engine with oil cooler similar.
Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
^ Tighten the large bolt to 57 Nm (42 ft. lbs).
^ Tighten the small bolt to 10 Nm (89 inch lbs).
68. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, install a new oil cooler, new gaskets and the 6 bolts.
^ Tighten to 10 Nm (89 inch lbs).
69. NOTE: Apply thread sealant with PTFE to the engine oil pressure (EOP) switch threads.
Install the EOP switch.
^ Tighten to 18 Nm (13 ft. lbs).
70. Install the crankshaft position (CKP) sensor and install the bolt.
^ Tighten to 10 Nm (89 inch lbs).
71. Install LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
72. Install and connect the CHT sensor jumper harness.
73. Using new gaskets, install the lower intake manifold and the 10 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs).
74. Using a new gasket, install the thermostat housing and the 3 bolts.
^ Tighten to 10 Nm (89 inch lb).
75. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
CAUTION: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
^ Remove the retaining clips and separate the fuel injectors from the fuel rail.
^ Remove and discard the O-ring seals.
^ Install new O-ring seals and lubricate with clean engine oil.
^ Install the fuel injectors and the retaining clips onto the fuel rail.
76. Install the fuel rail and injectors as an assembly and install the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs).
All wheel drive (AWD) vehicles
77. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 48 Nm (35 ft. lbs).
All vehicles
78. Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
79. Install the engine lifting eye and the 2 bolts.
^ Tighten to 24 Nm (18 ft. lbs).
80. Install the cover and the pin-type retainer.
81. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 ft. lbs) plus an additional 180 degrees.
82. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 ft. lbs).
83. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs).
84. Using new gaskets, install the RH exhaust manifold and 6 new nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs).
Front wheel drive (FWD) vehicles
85. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
^ Tighten to 40 Nm (30 ft. lbs).
All vehicles
86. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs).
87. Using new gaskets, install the LH exhaust manifold and 6 new nuts.
^ Tighten in the sequence shown to 20 Nm (15 ft. lbs).
88. Install the LH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
89. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
^ Tighten to 40 Nm (30 ft. lbs).
90. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs).
91. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
92. Install the generator, the bolt and the nut.
^ Tighten to 48 Nm (35 ft. lbs).
