Part 2
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material (Part 1):
Material (Part 2):
Major Upper Engine Components:
Engine - Front Components:
Cylinder Heads and Valve Train (Part 1):
Cylinder Heads and Valve Train (Part 2):
Lower End Components (Part 1):
Lower End Components (Part 2):
Assembly (Steps 45-88)
45. 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. Failure to follow this instruction may result in engine damage.
Carry out the following final tightening process on each bolt in the sequence shown.
^ Long bolts:
- Loosen and back out 3 turns.
- Tighten to 45 Nm (33 lb-ft).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
^ Short bolts:
- Loosen and back out 3 turns.
- Tighten to 25 Nm (18 lb-ft).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
46. 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.
47. NOTE: If reusing the rocker arms, make sure to install them in their original locations.
Install the 12 rocker arms.
^ Position the 12 rocker arms and pivots.
^ Hand-start the 12 bolts.
^ Tighten the bolts in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
48. Install the RH engine support insulator bracket and the 3 bolts.
^ Tighten to 48 Nm (35 lb-ft).
49. Inspect the RH exhaust manifold gasket sealing surfaces for flatness.
50. NOTE: Make sure the 2 long studs are installed in the locations noted during removal.
Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
51. Using a new gasket, install the RH exhaust manifold. Loosely install 6 new nuts.
52. Tighten the 6 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
53. Install a new RH valve cover gasket. Position the RH valve cover and install the bolts and stud bolts.
^ Tighten to 10 Nm (89 lb-in).
54. Install the following:
^ The LH engine support insulator and the bolts.
^ Tighten to 48 Nm (35 lb-ft).
^ The oil pressure sender.
^ Tighten to 27 Nm (20 lb-ft).
55. Inspect the LH exhaust manifold gasket sealing surfaces for flatness.
56. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
57. Using a new gasket, install the LH exhaust manifold. Loosely install 6 new nuts.
58. Tighten the new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
59. NOTE: Install a new oil level indicator tube O-ring seal. Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube and the retaining bolt.
^ Tighten to 10 Nm (89 lb-in).
60. Install a new valve cover gasket. Position the RH valve cover and install the bolts and stud bolts.
^ Tighten to 10 Nm (89 lb-in).
61. NOTE: If the lower intake manifold is not secured within 4 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.
Install the lower intake manifold front and rear seals.
1 Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal mounting points as indicated.
2 Install the lower intake manifold front and rear seals.
62. Install the intake manifold gaskets.
63. NOTE: If the lower intake manifold is not secured within 4 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.
Position the lower intake manifold.
1 Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and front and rear seal junctions in 4 places as shown.
2 Position the lower intake manifold.
64. NOTE: Make sure the bolts are installed in the correct locations. The long bolts are installed in positions 1, 2, 3, 4, 11 and 12.
Tighten the 14 bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).
65. NOTE: Clean and inspect the O-ring seal. Install a new O-ring seal if necessary. Lubricate the O-ring seal with clean engine coolant.
Position the heater outlet tube and install the nut. Connect the bypass hose.
^ Tighten to 10 Nm (89 lb-in).
66. Position the coolant pump pulley and install the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).
67. Position the engine wiring harness on the engine.
68. Connect and attach the heated oxygen sensor (HO2S) electrical connector. Connect the knock sensor (KS) and the cylinder head temperature (CHT) sensor electrical connectors.
69. Connect the oil pressure sender electrical connector and attach the wiring harness retainer.
70. Position the A/C compressor and power steering pump bracket and, if equipped, the A/C compressor and install the bolt finger tight.
71. Position the A/C and power steering pump bracket brace and install the 2 bolts and 2 nuts.
^ Tighten the 2 bolts to 48 Nm (35 lb-ft).
^ Tighten the 2 nuts to 25 Nm (18 lb-ft).
72. If equipped, attach the wiring harness retainer and connect the A/C compressor clutch electrical connector.
73. Connect the crankshaft position sensor (CKP) sensor and the camshaft position (CMP) electrical connectors.
^ Attach the 2 wiring harness retainers.
74. Position the generator mounting bracket, the generator, the accessory drive belt tensioner and the idler pulley as an assembly and install the 4 bolts.
^ Tighten the 3 lower bolts to 48 Nm (35 lb-ft).
^ Tighten the upper bolt to 25 Nm (18 lb-ft).
75. Install the accessory drive belt idler pulley and the bolt.
^ Tighten to 55 Nm (41 lb-ft).
76. Connect the heated PCV valve and the radio interference capacitor electrical connectors.
77. Connect and attach the HO2S electrical connector. Install the ground wire and the nut.
78. Install the special tool on the RH side.
79. Install the special tool on the LH side.
80. NOTE: Use two 10 mm (3/8 inch) spring links to connect the Engine Lifting Bracket 303-FO47 to the Engine Lifting Bracket 303-050.
Install the special tool.
81. Attach an engine crane to the Engine Lifting Bracket. Remove the engine from the stand.
82. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
83. Install the special tools on the rear of the crankshaft.
84. Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303-561) contacts the engine block.
85. Install the engine-to-transmission spacer plate.
Vehicles equipped with an automatic transmission
86. NOTE: Tighten the bolts evenly in a criss-cross pattern.
Install the flexplate and the 6 bolts.
^ Tighten to 80 Nm (59 lb-ft).
Vehicles equipped with a manual transmission
87. NOTE: Tighten the bolts evenly in a criss-cross pattern.
Position the flywheel and install the 6 bolts.
^ Tighten to 80 Nm (59 lb-ft).
88. NOTE: Tighten the bolts evenly in a criss-cross pattern.
NOTE: If reusing the clutch pressure plate and flywheel, make sure the marks made during disassembly line up.
Position the clutch pressure plate and the clutch disc and install the 6 bolts.
^ Tighten to 25 Nm (18 lb-ft).
