Steps 75-137

75. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.





76. Using new gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





77. Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





78. NOTICE: 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.

NOTE: 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.





79. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





All-Wheel Drive (AWD) vehicles

80. Install the catalytic converter bracket and the 2 bolts.
- Tighten to 48 Nm (35 lb-ft).





All vehicles

81. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





82. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





83. Install the cover and the pin-type retainer.





84. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.





85. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).





86. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





87. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).





Front Wheel Drive (FWD) vehicles

88. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





89. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





All vehicles

90. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





91. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).





92. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





93. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).





94. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).





95. Install the power steering pump and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).





96. Install the generator, the bolt and the nut.
- Tighten to 47 Nm (35 lb-ft).





97. Position the wiring harness onto the engine.

98. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.





99. Attach the wiring harness retainer to the generator.





100. Connect the generator electrical connector.