Part 3
EngineAssembly (Steps 48-78)
48. Install the camshaft position (CMP) sensor.
^ Tighten to 3 Nm (27 lb-inch).
49. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: If 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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Apply 4 beads of silicone gasket and sealant.
50. Install new intake manifold gaskets and end seals.
^ Position the intake manifold gaskets.
^ Position the end seals.
51. Install the lower intake manifold and bolts. Tighten in sequence shown.
^ Tighten to 29 Nm (21 lb-ft).
52. NOTE: Install new O-ring seals on the fuel injectors and lubricate them with clean engine oil.
Position the fuel rail and fuel injectors and install the bolts.
^ Tighten to 10 Nm (89 lb-inch).
53. Install the push rods and the rocker arms.
^ Install the push rods.
^ Install the rocker arms and bolts.
^ Tighten to 32 Nm (24 lb-ft).
54. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean the valve cover gasket sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Apply a bead of silicone gasket and sealant to the 4 intake-to-cylinder head seams.
55. Install new valve cover gaskets.
56. Install the valve covers and bolts. Tighten in the sequence shown.
^ Tighten to 12 Nm (9 lb-ft).
57. Using the special tool, install the crankshaft damper.
58. Install the bolt.
^ Tighten to 145 Nm (107 lb-ft).
59. Install the crankshaft pulley and the 4 bolts.
^ Tighten to 63 Nm (46 lb-ft).
60. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).
61. Install the generator mounting bracket and the bolts.
^ Tighten to 47 Nm (35 lb-ft).
62. Position the ignition coil assembly and install the bolts.
^ Tighten to 6 Nm (53 lb-inch).
63. Position the RH engine lifting eye and install the nuts.
^ Tighten to 20 Nm (15 lb-ft).
64. Position the LH engine lifting eye and install the nuts.
^ Tighten to 20 Nm (15 lb-ft).
65. Position the engine ground strap and install the bolt.
^ Tighten to 10 Nm (89 lb-inch).
66. Install the spark plug wires.
67. Position the wiring harness and attach the wiring harness retainers to the valve cover studs. Connect the fuel injector, engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
68. Connect the PCV valve and differential pressure feedback EGR sensor electrical connectors. Attach the wiring harness retainer to the differential pressure feedback EGR sensor.
69. Connect the CMP sensor, the oil pressure switch, and, if the vehicle is equipped with a manual transmission, the knock sensor (KS) electrical connectors. Attach the wiring harness and electrical connector retainers.
70. Attach the wiring harness retainer to the generator.
71. Attach the wiring harness retainer and connect the crankshaft position (CKP) sensor electrical connector.
72. Install the Lifting Eyes and the lifting equipment.
73. Remove the engine from work stand.
74. Install the engine-to-transmission spacer plate.
75. Install the flywheel or flexplate.
^ Tighten to 80 Nm (59 lb-ft).
Vehicles equipped with a manual transmission
76. Adjust the clutch pressure plate.
1 Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3 Release the pressure on the fingers. The adjusting ring will stay in the reset position.
77. Using the special tool, position the clutch disc on the flywheel.
78. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern.
^ Tighten to 32 Nm (24 lb-ft).
