Part 4

Engine

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.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G372 BA) and late build engines are built with engine code (1G372 CA).

All vehicles

136. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

Install the 3 LH spark plugs.

- Tighten to 15 Nm (133 lb-in).

137. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.

- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.





138. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.

- Tighten to 7 Nm (62 lb-in).





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

Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in the sequence shown in 2 stages:

- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.





140. Install the coolant pump pulley and the 4 bolts.

- Tighten to 24 Nm (18 lb-ft).





141. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

Install the thermostat housing and the 4 bolts and tighten in the sequence shown in 2 stages:

- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.





142. Install the heater hose bracket on the valve cover stud bolt and install the nut.

- Tighten to 8 Nm (71 lb-in).





143. Install the RH cylinder block drain plug.

- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.





144. Install the LH cylinder block drain plug.

- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.





145. Install the accessory drive belt tensioner and the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





146. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.





147. Lubricate the crankshaft front seal inner lip with clean engine oil.

148. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.





149. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages:

- Stage 1: Tighten to 120 Nm (89 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90 degrees.





150. Attach all of the wiring harness retainers to the LH cylinder head, valve cover and stud bolts.

151. Connect the CKP sensor electrical connector.





152. Install the wiring harness grommet.





153. Install the wiring harness retainer stud bolt.

- Tighten to 10 Nm (89 lb-in).





154. Install the heat shield, the nut and the bolt.

- Tighten to 10 Nm (89 lb-in).





155. Connect the 2 LH CMP sensors electrical connectors.

- Attach the wiring harness retainer to the rear of the cylinder head.





156. Connect the KS sensor electrical connector.





157. Connect the 2 LH VCT solenoid electrical connectors.





158. Connect the 3 LH fuel rail electrical connectors.





159. Connect the 3 LH ignition coil-on-plug electrical connectors.





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

- Attach the EOP switch wiring harness retainer to the cylinder head.





161. Attach all of the wiring harness retainers to the RH cylinder head, valve cover and stud bolts.

162. Connect the 2 RH CMP sensors electrical connectors.





163. Connect the 2 RH VCT solenoid electrical connectors.





164. Connect the 3 RH fuel rail electrical connectors.





165. Connect the CHT sensor wiring harness jumper electrical connector.





166. Connect the 3 RH ignition coil-on-plug electrical connectors.





167. Install the RH fuel rail insulator.





168. Install the LH fuel rail insulator.





169. Install the engine oil level indicator.





170. Install the LH engine support insulator-to-cylinder block bracket and the 4 bolts.

- Tighten to 63 Nm (46 lb-ft).





171. Install the RH engine support insulator and the 4 bolts.

- Tighten to 63 Nm (46 lb-ft).





172. Install the A/C compressor and the 3 bolts.

- Tighten to 25 Nm (18 lb-ft).





173. Install the LH and RH engine lift eyes.

- Tighten to 25 Nm (18 lb-ft).

174. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





175. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





176. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





177. Install the crankshaft sensor ring.





178. Install the spacer plate.





179. Install the flexplate and the 8 bolts and tighten is sequence shown.

- Tighten to 80 Nm (59 lb-ft).