Steps 81-116
Engine
Engine - Lower Engine Block (View 1)
Lower Engine Block (View 2)
Engine - Front Engine Block
Engine - Cylinder Head
Engine - Intake Manifold
NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.
NOTICE: 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 is loosened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage may occur.
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. For additional information, refer to Engine System - General Information Procedures.
81. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
82. Install the ignition coil and the 4 bolts.
- Tighten to 6 Nm (53 lb-in).
83. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots prior to installation.
Connect the spark plug wires to the spark plugs.
84. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
85. Connect the ignition coil and the CHT sensor electrical connectors. Position the CHT sensor cover.
86. Connect the fuel injector electrical connectors and attach the wiring harness pin-type retainers.
87. Inspect and install new intake manifold gaskets, if necessary.
88. 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.
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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Install the intake manifold and the 5 bolts.
- Tighten to 18 Nm (159 lb-in).
89. Install the EGR tube.
- Install the EGR tube bracket and the bolt to the intake manifold.
- Tighten to 10 Nm (89 lb-in).
- Connect the EGR tube to the cylinder head.
- Tighten to 55 Nm (41 lb-ft).
90. Connect the EGR tube to the intake manifold.
- Tighten to 18 Nm (159 lb-in).
91. Attach the engine wiring harness pin-type retainers to the intake manifold.
92. Connect the CMP sensor electrical connector and the PCV hose.
93. Install the engine wiring harness connector bracket, the 3 bolts and connect the KS electrical connector.
- Tighten to 10 Nm (89 lb-in).
94. Connect the CKP sensor electrical connection and attach the wiring pin-type retainers.
95. Connect the following electrical connectors:
- Manifold Absolute Pressure (MAP) sensor
- Throttle Position (TP) sensor
- Idle Air Control (IAC) valve
96. Install the power steering pump assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
97. 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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Install the EGR valve.
1. Using a new gasket, position the EGR valve and install the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
2. Connect the coolant hose.
3. Connect the electrical connector.
98. 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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Install the rear coolant outlet pipe.
1. Using a new gasket, install the rear coolant outlet pipe and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
2. Connect the coolant hose.
99. If equipped, install the block heater.
100. Install 7 new exhaust manifold-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).
101. Position a new gasket and install the exhaust manifold and 7 new nuts.
- Tighten to 54 Nm (40 lb-ft).
102. Position the coolant tube assembly and install the 2 nuts.
- Tighten to 20 Nm (177 lb-in).
103. Connect the coolant hose to the thermostat and the PCV fitting on the intake manifold.
104. Position the right motor mount and install the 4 bolts.
- Tighten to 49 Nm (36 lb-ft).
105. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown, in 2 stages.
- Stage 1: Install finger-tight.
- Stage 2: Tighten to 47 Nm (35 lb-ft).
106. Position the A/C compressor and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
107. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation.
Position the front coolant outlet pipe and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
108. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the engine oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
109. Install the accessory drive belt.
110. Using the Spreader Bar and the Heavy Duty Floor Crane, remove the engine from the Engine Stand.
111. Position the flywheel or the flexplate and loosely install the 6 bolts.
112. Using the Flywheel Locking Tool, tighten the 6 bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
Vehicles with manual transmission
113. Lubricate the transmission input shaft pilot bearing with front axle grease.
114. Adjust the clutch pressure plate.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
115. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
116. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the 6 bolts. Tighten the bolts in a star pattern sequence.
- Tighten to 32 Nm (24 lb-ft).
