Part 3

Engine





























Assembly (Steps 75-111)

75. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Loosely install the RH camshaft sprocket bolt.





76. Install the bolt.
^ Tighten to 10 Nm (89 lb-in).





77. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Loosely install the LH camshaft sprocket bolt.





78. Install the bolt.
^ Tighten to 12 Nm (9 lb-ft).





79. Turn the crankshaft one revolution clockwise.

80. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.

NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).

Install the special tool.





81. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.





82. NOTE: Leave the top 2 special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.





83. Install the special tool.





84. NOTE: The RH camshaft sprocket bolt is a left-hand threaded bolt.

Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
2 Tighten the camshaft bolt to 85 Nm (63 lb-ft).





85. Remove the special tool and install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 lb-ft).





86. NOTE: Do not tighten the special tool top 2 clamp bolts. The camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.





87. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the LH cylinder head.





88. Install the special tool.





89. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
2 Tighten the camshaft bolt to 85 Nm (63 lb-ft).





90. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 lb-ft).





91. Rotate the crankshaft until the cam lobe is in the up position.





92. NOTE: Lubricate the parts with clean engine oil.

Using the special tool, install the roller followers in their original positions.





93. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness.
94. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
95. Install a new gasket, the RH exhaust manifold and the new nuts.
^ Tighten to 22 Nm (16 lb-ft).





96. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
97. Install a new gasket, the LH exhaust manifold and the new nuts.
^ Tighten to 22 Nm (16 lb-ft).





98. NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging.

Install the knock sensor (KS) and the bolt.
^ Tighten to 20 Nm (15 lb-ft).





99. Install the oil level indicator tube and bolt.





100. Position the thermostat housing and bypass hose on the coolant pump.
1 Install the bolts.
^ Tighten to 11 Nm (8 lb-ft).
2 Position the bypass hose clamp.





101. NOTE: RH valve cover shown, LH similar.

Install the valve covers and tighten the bolts.
^ Tighten to 10 Nm (89 lb-in).





102. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals may cause the fuel system to leak. Do not reuse the O-ring seals.

Install new O-ring seals on each of the fuel injectors.





103. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.

Install the fuel injectors.





104. Install the fuel rail and the bolts.
^ Tighten to 24 Nm (18 lb-ft).





105. Position the fuel supply tube and install the bolt.
^ Tighten to 6 Nm (53 lb-in).





106. NOTE: LH shown, RH similar.

Install the LH and RH insulator brackets and the bolts.
^ Tighten to 80 Nm (59 lb-ft).





107. Install the oil pressure switch.
^ Tighten to 13 Nm (10 lb-ft).





108. Position the battery cable and harness and attach the retainers.





109. Connect the oil pressure switch electrical connector. Position the battery cable and harness bracket and install the nut.
^ Tighten to 20 Nm (15 lb-ft).





110. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.





111. Position the engine wiring harness on the engine.