Steps 71-120
Engine
Upper End - 4.0L SOHC Engine
Lower End - 4.0L SOHC Engine
All vehicles
NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.
NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play.
NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
71. Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
72. Position the Crankshaft Position (CKP) sensor and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
73. NOTE: LH shown, RH similar.
Install the cylinder head gaskets.
74. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
75. Install 2 new 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
76. Tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
77. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the RH camshaft sprocket bolt.
78. Install the RH cassette-to-cylinder head bolt.
- Tighten to 10 Nm (89 lb-in).
79. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the LH cylinder head and tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
80. Install 2 new 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
81. Tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
82. Position the LH camshaft sprocket.
83. NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the LH camshaft sprocket bolt.
84. Install the LH cassette-to-cylinder head bolt.
- Tighten to 12 Nm (106 lb-in).
85. Turn the crankshaft one revolution clockwise.
86. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the engine at Top Dead Center (TDC).
Install the Crankshaft TDC Timing Tool.
87. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft.
Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head.
88. NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH cylinder head.
89. Install the Timing Chain Tensioner.
90. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
Tighten the bolts.
1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
91. Install a new washer and the RH timing chain tensioner.
- Tighten to 44 Nm (32 lb-ft).
92. NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts. The camshaft sprocket must rotate freely.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head.
93. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft.
Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the LH cylinder head.
94. Install the Timing Chain Tensioner.
95. Tighten the bolts.
1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
96. Install a new washer and the LH timing chain tensioner.
- Tighten to 44 Nm (32 lb-ft).
97. NOTE: Install the hydraulic lash adjuster in the same positions from which they were removed.
Install the hydraulic lash adjusters.
98. Rotate the crankshaft until the cam lobe on the cylinder being serviced is in the up position.
99. NOTE: Lubricate the parts with clean engine oil.
Using the Valve Spring Compressor, install the roller followers in their original positions.
100. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness.
101. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
102. Install a new gasket, the RH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).
103. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
104. Install a new gasket, the LH exhaust manifold and the 6 new nuts.
- Tighten to 22 Nm (16 lb-ft).
105. NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging.
Install the Knock Sensor (KS) and the bolt.
- Tighten to 20 Nm (177 lb-in).
106. Install the oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
107. Position the thermostat housing and bypass hose on the coolant pump.
1. Install the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
2. Position the bypass hose clamp.
108. NOTE: RH valve cover shown, LH similar.
Install the valve covers and tighten the 12 bolts.
- Tighten to 10 Nm (89 lb-in).
109. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals may cause the fuel system to leak. Do not reuse the O-ring seals.
Install new O-ring seals on each of the fuel injectors.
110. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.
Install the fuel injectors.
111. Install the fuel rail and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
112. Position the fuel supply tube and install the bolt.
- Tighten to 6 Nm (53 lb-in).
113. NOTE: LH shown, RH similar.
Install the LH and RH insulator brackets and the 6 bolts.
- Tighten to 80 Nm (59 lb-ft).
114. Install the oil pressure switch.
- Tighten to 13 Nm (115 lb-in).
115. Position the battery cable and harness and attach the retainers.
116. Connect the oil pressure switch electrical connector. Position the battery cable and harness bracket and install the nut.
- Tighten to 20 Nm (177 lb-in).
117. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.
118. Position the engine wiring harness on the engine.
119. Position the engine wiring harness retainer and install the bolt.
- Tighten to 47 Nm (35 lb-ft).
120. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
