Part 3
EngineAssembly (Steps 83-122)
83. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-inch).
2 Tighten the camshaft bolt.
^ Tighten to 85 Nm (63 lb-ft).
84. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 lb-ft).
85. Rotate the crankshaft until the cam lobe is in the UP position.
86. NOTE: Lubricate the parts with clean engine oil prior to installing.
Using the special tool, install the roller followers in their original positions.
87. Clean and inspect the LH and RH exhaust manifolds.
88. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
89. Install a new gasket, the LH exhaust manifold and new nuts.
^ Tighten to 22 Nm (16 lb-ft).
90. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
91. Install a new gasket, the RH exhaust manifold and new nuts.
^ Tighten to 22 Nm (16 lb-ft).
92. 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 lb-ft).
93. Install the oil level indicator tube and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
94. Install the thermostat housing.
1 Position the housing and the bypass hose and install the bolts.
^ Tighten to 11 Nm (8 lb-ft).
2 Position the bypass hose clamp.
95. Install the gasket, the RH valve cover and the bolts.
^ Tighten to 10 Nm (89 lb-inch).
96. Install the gasket, the LH valve cover and the bolts.
^ Tighten to 10 Nm (89 lb-inch).
97. Install the fuel rail and the fuel injectors as an assembly. Install the fuel rail bolts.
^ Tighten to 23 Nm (17 lb-ft).
98. Install the EGR valve tube to the exhaust manifold.
^ Tighten to 34 Nm (25 lb-ft).
99. Position the engine wiring harness.
100. Connect new wiring harness retainers.
101. Connect the crankshaft position (CKP) sensor electrical connector.
102. Position the coolant tube and bracket, the PCV hose-to-intake manifold fitting and the PCV hose as an assembly and install the bolts.
^ Tighten the large bolt to 28 Nm (21 lb-ft) and the small bolt to 23 Nm (17 lb-ft).
103. Attach the wiring harness retainer.
104. Connect the coolant hose.
105. Connect the coolant hose.
106. Position the bracket and install the bolt.
^ Tighten to 28 Nm (21 lb-ft).
107. Connect the KS and engine coolant temperature (ECT) sensor electrical connectors.
108. Attach the 2 wiring harness retainers to the valve cover studs and connect the 6 fuel injector electrical connectors.
109. Connect the camshaft position (CMP) sensor and differential pressure feedback EGR sensor electrical connectors. Attach the wiring harness retainer. Position the electrical connector bracket and install the bolt.
^ Tighten to 6 Nm (53 lb-inch).
110. Connect the PCV valve hose and electrical connector.
111. Attach the electrical connector. Position the ground wire and install the bolt.
^ Tighten to 25 Nm (18 lb-ft).
112. Install the generator bracket.
1 Install the generator bracket and bolts.
^ Tighten to 42 Nm (31 lb-ft).
2 Install the accessory drive belt tensioner and bolt.
^ Tighten to 47 Nm (35 lb-ft).
113. NOTE: The lifting brackets should be installed on the exhaust manifold studs for No. 3 and No. 4 cylinders.
Install the Engine Lifting Brackets.
114. Install the Spreader Bar to the Engine Lifting Brackets.
115. Attach a floor crane to the Spreader Bar and remove the engine from the engine stand.
116. 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.
117. Install the special tools.
118. Position the crankshaft rear seal.
119. Using the special tool, install the crankshaft rear seal.
120. Install the crankshaft spacer.
121. Install the crankshaft spacer plate.
122. NOTE: Special bolts are used for flexplate or flywheel installation. Do not use standard bolts.
Install the flexplate or flywheel. Tighten the bolts in 3 stages in the sequence shown.
^ Stage 1: Tighten to 13 Nm (10 lb-ft).
^ Stage 2: Tighten to 50 Nm (37 lb-ft).
^ Stage 3: Tighten an additional 90 degrees.
