Part 4

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. 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.

70. Using the Crankshaft Sensor Aligner, adjust the CKP (Crankshaft Position) sensor.
- Tighten the 2 CKP (Crankshaft Position) bolts to 7 Nm (62 lb-in).






71. Remove the 6 mm x 18 mm bolt.





72. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.





73. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).






74. 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.

Clean the valve cover gasket surface with metal surface prep.


75. Apply silicone gasket and sealant to the locations shown.





76. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.
Install the valve cover.

- Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).






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

Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
- Tighten the CHT (Cylinder Head Temperature) sensor to 12 Nm (106 lb-in).

- Tighten the spark plugs to 12 Nm (106 lb-in).






78. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 ignition coil-on-plugs and the 4 bolts.

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






79. Install the intermediate shaft bracket and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).






80. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).






81. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS (Knock Sensor) 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).