Part 2

Engine















Lower Engine Block











Cylinder Heads and Intake Manifolds













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 may cause engine failure.

NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

69. Install the belt tensioner and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





70. Install the 8 nuts and the oil pan baffle in the following sequence.

1. Tighten the 4 M6 oil pan baffle nuts in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten an additional 45 degrees.

2. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten an additional 45 degrees.





71. Install a new O-ring seal on the oil pump screen and pickup tube.
- Lubricate the O-ring seal with clean engine oil.





72. Install the oil pump screen and pickup tube.

1. Position the oil pump screen and pickup tube.

2. Install the 2 bolts and tighten to 10 Nm (89 lb-in).





73. Install the new gasket in the LH valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.





74. NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.

NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.

Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.





75. Position the LH valve cover and install the bolts and stud bolts.

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





76. Install the new gasket in the RH valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.





77. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.





78. Position the RH valve cover and install the bolts and stud bolts.

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





79. Install the radio interference capacitor and the nut.
- Tighten to 6 Nm (53 lb-in).





80. Position the coolant pump housing and attach the coolant hose.
- Tighten the clamp to 7 Nm (62 lb-in).





81. Install the 5 coolant pump housing bolts.
- Tighten to 10 Nm (89 lb-in).





82. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.

- Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.





83. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).

Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration.
- Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.





84. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.





85. NOTICE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.

Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.

86. Lubricate the O-ring seal with clean engine oil and install the oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.





87. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater.
- Tighten the EOP switch to 14 Nm (124 lb-in).

- Tighten the block heater to 21 Nm (15 lb-ft).





88. Install 6 new LH catalytic converter studs.
- Tighten to 12 Nm (106 lb-in).





89. Install a new gasket and the LH catalytic converter and 6 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).





90. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.





91. Position the oil level indicator and tube and install the stud bolt.
- Tighten to 10 Nm (89 lb-in).





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





93. Install the 3 bolts and the A/C compressor bracket.
- Tighten to 25 Nm (18 lb-ft).





94. Position the generator and install the bolt and 2 nuts.
- Tighten to 47 Nm (35 lb-ft).





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





96. Install a new gasket and the RH exhaust manifold and new nuts.
- Tighten the nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).





FWD vehicles

97. Install a new gasket and the RH catalytic converter and the 3 new nuts.
- Tighten to 40 Nm (30 lb-ft).





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





99. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.





All vehicles

100. NOTE: LH shown, RH similar. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

Install the 6 coil-on-plugs and the bolts.
- Tighten to 6 Nm (53 lb-in).





101. 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.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the lower intake manifold and install the 8 bolts.

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





102. 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.





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





104. 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.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the upper intake manifold and install the 7 bolts.

- Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.





105. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown), then tighten all the bolts.
- Tighten to 10 Nm (89 lb-in).





106. Install the EGR tube fitting in the EGR valve.
- Tighten to 40 Nm (30 lb-ft).





107. Position and attach the 3 B+ wiring harness retainers.





108. Install the B+ wire and nut on the generator.
- Tighten to 8 Nm (71 lb-in).





109. Connect the 3 LH coil-on-plug electrical connectors.
- Attach the 2 wiring harness retainers.





110. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.





111. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.





112. Connect the LH VCT electrical connector.





113. Connect the fuel injector wiring harness electrical connector.





114. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.





115. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.





116. Connect the RH VCT electrical connector.





117. Connect the RH coil-on-plug electrical connectors.
- Attach the 2 wiring harness retainers.





FWD vehicles

118. Connect the RH HO2S electrical connector.





All vehicles

119. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.





120. Attach the wiring harness retainer to the upper intake manifold.





121. Connect the EGR regulator electrical connector and attach the wiring retainer.





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





123. Connect the electronic throttle control electrical connector.





124. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.





125. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.