Part 4
Engine
Engine Upper
Engine Front
Engine Lower (View 1)
Lower Engine (View 2)
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may 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.
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE: The Differential Bearing Cone Installer is used to install the Variable Camshaft Timing (VCT) solenoid seals.
136. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).
137. Connect the A/C compressor electrical connector.
138. Connect the CKP (Crankshaft Position) sensor electrical connector.
139. Install the wiring harness grommet.
140. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).
141. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).
142. Install the ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).
143. Connect the CHT (Cylinder Head Temperature) sensor electrical connector.
144. Connect the KS (Knock Sensor) electrical connector.
145. Connect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
146. Attach the wiring harness retainer.
147. Connect the 3 fuel injector electrical connectors.
- Attach the 2 wiring harness retainers.
148. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
- Attach the 2 wiring harness retainers.
149. NOTE: On All-Wheel Drive (AWD) vehicles the Catalyst Monitor Sensor (CMS) electrical connector will be connected during the engine installation procedure.
Connect the HO2S (Heated Oxygen Sensor) and CMS (Catalyst Monitor Sensor) electrical connectors.
- Attach the 2 wiring harness retainers to the RH valve cover.
150. Connect the 3 RH coil-on-plug electrical connectors.
151. Using a new gasket, install the intake manifold and the 7 bolts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
152. Install the upper intake manifold support bracket bolt.
- Tighten to 10 Nm (89 lb-in).
153. Connect the crankcase ventilation hose to the Positive Crankcase Ventilation (PCV) valve.
154. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
155. Connect the EVAP (Evaporative Emission) vapor tube to the EVAP (Evaporative Emission) canister vent solenoid.
- Attach the pin-type retainer.
156. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors.
- Attach the wiring harness pin-type retainer.
157. Attach the wiring harness retainer to the intake manifold.
158. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
- Install the wiring harness retainer to the rear of the LH cylinder head.
159. Connect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
160. NOTE: Coolant hose removed from graphic for clarity.
Attach the 2 wiring harness retainers.
161. Connect the 3 fuel injector electrical connectors.
- Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
162. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
- Attach the wiring harness connector pin-type retainer to the LH valve cover.
163. Attach the 2 wiring harness pin-type retainers.
164. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
- Attach the wiring harness pin-type retainer.
165. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
166. Attach the wiring harness connector pin-type retainer to the LH valve cover.
167. Connect the 3 LH coil-on-plug electrical connectors.
168. Install the crankcase vent tube.
169. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
170. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
171. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
172. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
173. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
174. If equipped, connect the block heater electrical connector and install the heat shield.
175. Install the Engine Lift Eye on the LH cylinder head.
176. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
177. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
178. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
179. Install the crankshaft sensor ring.
180. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts.
- Tighten in the sequence shown to 80 Nm (59 lb-ft).
