Part 2

Engine















Lower Engine Block











Front Engine Block











Cylinder Head











Intake Manifold









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

67. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
- Tighten the 8-mm bolts to 10 Nm (89 lb-in).

- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).





68. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.





69. NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





70. NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.





71. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

- Stage 1: Tighten to 100 Nm (74 lb-ft).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).





72. Remove the 6 mm x 18 mm bolt.





73. Remove the Crankshaft TDC Timing Peg.





74. Remove the Camshaft Alignment Plate.





75. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourth turns.

76. Install the Crankshaft TDC Timing Peg.





77. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.





78. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.

- If it is not possible to install the bolt, the engine valve timing must be corrected.





79. Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.





80. Remove the Camshaft Alignment Plate.





81. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.





82. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
- Tighten the 2 CKP bolts to 7 Nm (62 lb-in).





83. Remove the 6 mm x 18 mm bolt.





84. Remove the Crankshaft TDC Timing Peg.





85. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).





86. NOTICE: 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.

Clean the valve cover gasket surface with metal surface prep.

87. Apply silicone gasket and sealant to the locations shown.





88. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover.

- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).





89. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.

Install the oil level indicator.





90. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.

Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (106 lb-in).
^ Tighten the spark plugs to 12 Nm (106 lb-in).





91. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 coil-on-plugs and the 4 bolts.
^ Tighten to 8 Nm (71 lb-in).





92. Install the engine cover studs.





93. Install the crankcase vent tube.





94. If equipped, install the block heater.
- Tighten to 21 Nm (15 lb-ft).





95. NOTE: Clean the gasket mating surfaces with metal surface cleaner.

NOTE: Spin-on oil filter adapter shown, element oil filter adapter similar.

Install the oil filter adapter with a new gasket.
^ Tighten to 25 Nm (18 lb-ft).





96. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).





97. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

Install the KS and the bolt.

- Tighten to 20 Nm (177 lb-in).





98. Install the vacuum pump assembly, the nut and the 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).





99. Install the coolant hose.





100. Install the coolant hose.





101. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.

Install the thermostat housing.
^ Tighten to 10 Nm (89 lb-in).





102. Connect the EGR coolant hose and the heater hose.





103. Install the coolant hose.





104. NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

Install the coolant pump and bolts.
- Tighten to 10 Nm (89 lb-in).





105. Install the coolant pump pulley and bolts.
- Tighten to 20 Nm (177 lb-in).





106. Position the engine control wiring harness on the engine.

107. Attach the wiring harness retainer to the valve cover stud.
^ Connect the EGR valve electrical connector





108. Connect the CHT sensor and install the rubber boot.





109. Connect the 4 coil-on-plug electrical connectors.





110. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

Install new fuel injector O-rings.
^ Separate the fuel injectors from the fuel rail.
^ Remove and discard the fuel injector O-rings.
^ Install new O-rings and lubricate with clean engine oil.
^ Install the fuel injectors onto the fuel rail.





111. Install the fuel rail with the fuel injectors and stud bolts.
- Tighten to 23 Nm (17 lb-ft).





112. Install the radio capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).





113. Install the fuel rail insulator.





114. Position the high voltage wiring harness and attach the 2 wiring harness retainers to the ignition coil stud bolts.





115. Connect the VCT electrical connector and attach the wiring harness retainer to the valve cover stud bolt.





116. Attach the 2 wiring harness retainers to the fuel rail and from the valve cover.





117. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.





118. Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).





119. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Position the intake manifold and connect the PCV hose.





120. NOTE: Inspect and install new intake manifold gaskets, if necessary.

Install the intake manifold gasket, intake manifold and 7 bolts.

- Tighten to 18 Nm (159 lb-in).





121. Attach the 4 wire harness pin-type retainers to the intake manifold.





122. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.





123. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.





124. Connect the Engine Oil Pressure (EOP) switch electrical connector.





125. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.





126. Connect the electronic throttle control electrical connector.