Steps 81-116
Engine
Lower Engine Block (View 1)
Lower Engine Block (View 2)
Front Engine Block
Cylinder Head
Intake Manifold
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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.
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 Service and Repair.
81. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS and the bolt.
- Tighten to 20 Nm (177 lb-in).
82. Install the A/C compressor, 2 bolts and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
83. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
Install the thermostat housing and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
84. Connect the coolant bypass hose.
85. Using a new gasket, install the coolant outlet and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
86. Connect the coolant bypass hose.
87. Install the radio interference capacitor bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
88. Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
89. Inspect and install new intake manifold gaskets if necessary.
90. 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.
Position the intake manifold and connect the PCV hose.
91. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
Install the intake manifold and hand-tighten the 2 intake manifold bolts.
92. Install the 5 intake manifold mounting bolts.
- Tighten all 7 bolts to 18 Nm (159 lb-in).
93. NOTE: Lubricate the new O-ring with clean engine oil.
Using a new O-ring seal, install the oil level indicator tube assembly and the bolt.
- Tighten to 10 Nm (89 lb-in).
94. Install the lower intake manifold bolt.
- Tighten to 18 Nm (159 lb-in).
95. Connect the EGR valve electrical connector.
96. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- Attach the 3 wiring harness retainers to the intake manifold.
97. Connect the throttle control electrical connector.
98. Connect the KS electrical connector and pin-type retainer.
99. 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.
100. Install the fuel rail with the fuel injectors and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
101. Connect the 4 fuel injector electrical connectors and attach the 4 wiring harness retainers to valve cover stud bolts and intake manifold.
102. Attach the wiring harness retainer on the valve cover stud.
103. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
104. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
105. NOTE: Clean the gasket mating surfaces with metal surface prep.
Using a new gasket, install the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
106. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Install a new oil cooler and bolt.
- Tighten to 34 Nm (25 lb-ft).
107. NOTE: Lubricate the oil filter gasket with clean engine with clean engine oil prior to installation.
Install the oil filter.
- Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
108. Connect the oil cooler hoses.
109. Connect the Engine Oil Pressure (EOP) switch electrical connector.
110. Connect the EGR valve coolant hose.
111. Connect the oil cooler hose and lower radiator hose to the thermostat housing.
112. NOTE: Clean the coolant pump mating surface with metal surface prep.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
Position the coolant pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
113. Install the coolant pump pulley and 3 bolts.
- Tighten to 20 Nm (177 lb-in).
114. Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
115. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
116. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (50 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
