Part 3
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, can cause engine failure.
NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
NOTE: During engine assembly it may become necessary to check bearing clearances and end play.
All engines
Engines not equipped with an A/C belt tensioner
100. Position the A/C compressor belt in 2 stages.
- Stage 1: Slide the A/C compressor belt between the crankshaft pulley and the accessory drive belt tensioner.
- Stage 2: Position the A/C compressor belt behind the crankshaft pulley with the accessory drive belt ribs facing towards the front of the vehicle.
NOTE: Make sure the A/C compressor belt is correctly seated on the A/C compressor pulley.
- Stage 3: Position the A/C compressor belt onto the A/C compressor pulley with the lower portion of the accessory drive belt ribs facing towards the front of the vehicle and above the oil pan as shown.
101. NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and A/C compressor pulleys.
Position the A/C compressor belt onto the top of the crankshaft pulley and feed a tie strap with a minimum width of 3 mm (0.12 in) through the crankshaft pulley spokes, up and over the A/C compressor belt and tighten the tie strap.
102. NOTICE: The A/C compressor belt must be above the oil pan flange or damage to the A/C compressor belt and engine can occur.
With the A/C compressor belt positioned above the oil pan flange, rotate the crankshaft by hand clockwise until the tie strap is at the 6 o'clock position.
103. NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and A/C compressor pulleys.
Remove the tie strap and rotate the crankshaft clockwise 1 full rotation to verify the A/C compressor belt has correctly seated onto the crankshaft and A/C compressor pulleys.
All engines
104. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
105. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft)
.
106. Connect the 2 coolant hoses to the oil cooler.
107. NOTE: Lubricate the new thermostat housing O-ring seal with clean engine coolant.
Using a new thermostat housing O-ring seal, install the thermostat housing and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
108. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
109. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).
110. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.
111. Position the LH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
112. Install the oil level indicator.
113. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
114. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).
115. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.
116. Position the RH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
117. Position the wiring harness on the engine.
- Connect the 2 KS electrical connectors.
118. Install the ground wire and nut to the engine front cover stud bolt.
- Tighten to 10 Nm (89 lb-in).
119. Attach the wiring harness retainer to the engine front cover stud bolt.
120. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness retainers.
121. If removed, install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the LH intake and exhaust CMP sensor electrical connectors.
122. Install the heat shield and the 2 bolts to the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).
123. Connect the CHT sensor and the CKP sensor electrical connectors.
124. Install the RH intake and exhaust CMP sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the RH intake and exhaust CMP sensor electrical connectors.
125. Install the heat shield, the bolt and the stud bolt on the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).
126.Connect the 2 VCT variable force solenoid electrical connectors.
- Attach the 10 wiring harness retainers to the LH valve cover.
127. Connect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
- Attach the 10 wiring harness retainers to the RH valve cover.
128. 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.
129. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown, LH similar.
Install the 8 ignition coils and 8 bolts.
- Tighten to 6 Nm (53 lb-in).
130. NOTE: RH shown, LH similar.
Connect the 8 ignition coil electrical connectors.
131. Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
132. Install a new gasket, the RH exhaust manifold and 8 new nuts.
- Tighten the nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
133. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 12 Nm (106 lb-in).
134. Install 8 new LH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
135. Install a new gasket, the LH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
136. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 12 Nm (106 lb-in).
137. Install the RH engine support insulator and the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).
138. Install the LH engine support insulator bracket and the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).
139. Install the Engine Lifting Bracket
140. Using the Floor Crane, remove the engine from the work stand.
141. 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.
142. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
143. Install the crankshaft sensor ring.
144. Install the engine separator plate.
145. NOTE: The flexplate bolts are torque-to-yield design and are not reusable.
Install the engine separator plate, the flexplate and 8 new bolts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
