Part 4

Engine














Engine - Upper End














Engine - Front End














Engine - Lower End










76. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.


77. NOTE: If the valve cover is not secured within 6 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.






78. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) variable force solenoid.

Position the RH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






79. NOTE: If the valve cover is not secured within 6 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.






80. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) variable force solenoid.

Position the LH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






81. Install the oil level indicator tube and the bolt.
- Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.

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






82. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).






83. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).






84. NOTE: LH shown, RH similar.

Install 16 new exhaust manifold studs.

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






85. Using new exhaust manifold nuts, position the LH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).






86. Position the LH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).






87. Using new exhaust manifold nuts, position the LH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).






88. Position the RH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).






89. Install the 2 Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).






90. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the LH and RH Camshaft Position (CMP) sensors and the 2 bolt.

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






91. NOTE: RH shown, LH similar.

Connect the 8 ignition wires to the valve cover retainers and the lower spark plugs.






92. Position the wiring harness onto the engine assembly.

93. Connect the 3 engine wiring harness position retainers to the RH valve cover.





94. Connect the RH VCT (Variable Camshaft Timing) variable force solenoid electrical connector and the 2 wiring harness retainers.





95. Position the radio ignition interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).






96. Position the ground cable and install the nut.
- Tighten to 25 Nm (18 lb-ft).






97. Connect the LH and RH CMP (Camshaft Position) electrical connectors.





98. Connect the wiring harness retainer, the KS (Knock Sensor) and Cylinder Head Temperature (CHT) sensor electrical connectors.





99. Connect the 3 engine wiring harness position retainers to the LH valve cover.





100. Connect the LH VCT (Variable Camshaft Timing) variable force solenoid electrical connector and the 2 wiring harness retainers.





101. Connect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainers.





102. Install the Engine Lifting Bracket and Engine Support Brackets.





103. Using a suitable floor crane, remove the engine from the engine stand.

104. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.

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






105. NOTE: Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be discarded.

With the inset hole on the crankshaft ignition pulse ring aligned with the inset hole on the crankshaft flange, install the crankshaft ignition pulse ring.






106. NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP (Crankshaft Position) sensor is installed incorrectly, the CKP (Crankshaft Position) sensor can be damaged.

Position the Crankshaft Position (CKP) sensor, install the bolt and connect the electrical connector.
- Tighten to 10 Nm (89 lb-in).






107. Remove the engine rear cover plate.





108. With the offset hole on the crankshaft ignition pulse ring aligned with the offset hole on the flexplate, position the flexplate and install 8 new bolts finger-tight.





109. Tighten the 8 new bolts in 6 stages.
- Stage 1: Tighten fasteners 1 through 4 in sequence to 20 Nm (177 lb-in).

- Stage 2: Tighten fasteners 1 through 4 in sequence to 35 Nm (26 lb-ft).

- Stage 3: Tighten fasteners 1 through 4 in sequence an additional 60 degrees.

- Stage 4: Tighten fasteners 5 through 8 in sequence to 20 Nm (177 lb-in).

- Stage 5: Tighten fasteners 5 through 8 in sequence to 35 Nm (26 lb-ft).

- Stage 6: Tighten fasteners 5 through 8 in sequence an additional 60 degrees.






110. Rotate the crankshaft clockwise until the 2 flexplate slotted holes are at the 6 o'clock position as shown prior to engine installation.