Part 3
Engine
Assembly (Steps 95-142)
95. 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).
96. Install the LH camshaft tensioner.
97. Rotate the crankshaft until the cam lobe is in the upward position.
98. NOTE: Lubricate the roller followers with clean engine oil.
Using the special tool, install the roller followers in their original positions.
99. Position the RH engine mount bracket and install the 4 bolts.
^ Tighten to 80 Nm (59 lb-ft).
100. Install the 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
101. Position a new RH exhaust manifold gasket and the RH exhaust manifold. Install the 6 new nuts.
^ Tighten to 23 Nm (17 lb-ft).
102. Position the LH engine mount bracket and install the 3 bolts.
^ Tighten to 80 Nm (59 lb-ft).
103. Install the 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
104. Position a new LH exhaust manifold gasket and the LH exhaust manifold. Install the 6 new nuts.
^ Tighten to 23 Nm (17 lb-ft).
105. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil.
Position the oil level indicator tube and install the bolt.
^ Tighten to 11 Nm (8 lb-ft).
106. Clean the valve covers and cylinder head sealing surfaces with metal surface prep. Inspect and install new gaskets as necessary.
107. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
108. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
109. Position the thermostat housing, hoses and coolant tube. Install the 3 bolts.
^ Tighten to 11 Nm (8 lb-ft).
110. Connect the coolant hose to the coolant pump, position the bracket and install the bolt.
^ Tighten to 45 Nm (33 lb-ft).
111. Position the knock sensor (KS) and install the bolt.
^ Tighten to 20 Nm (15 lb-ft).
112. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine oil.
Install new O-ring seals on the 6 fuel injectors.
113. Position the fuel rail and injectors and install the 4 bolts.
^ Tighten to 23 Nm (17 lb-ft).
114. Position the main engine wiring harness on the engine and install the 3 bolts.
^ Tighten to 40 Nm (30 lb-ft).
^ Attach the wiring retainers.
115. Connect the 3 RH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.
116. Connect the 3 LH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.
117. Connect the PCV valve electrical connector.
118. Connect the engine coolant temperature (ECT) sensor electrical connector.
119. Connect the crankshaft position (CKP) sensor electrical connector and attach the 2 wiring retainers.
120. Position the generator and bracket. Install the 2 bolts and the nut.
^ Tighten to 47 Nm (35 lb-ft).
121. Install the accessory drive belt tensioner and the bolt.
^ Tighten to 47 Nm (35 lb-ft).
122. Connect the engine oil pressure (EOP) switch electrical connector and attach the wiring retainer.
123. Connect the camshaft position (CMP) electrical connector.
124. Position the fuel rail supply tube brackets and install the 2 bolts.
^ Tighten the bolt for the upper bracket to 6 Nm (53 lb-in).
^ Tighten the bolt for the lower bracket to 10 Nm (89 lb-in).
125. NOTE: Clean and inspect all sealing surfaces. Inspect and install new intake manifold gaskets as necessary.
Position the intake manifold and install the 8 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
126. Connect the KS electrical connector and attach the wiring retainer.
127. Install the PCV tube.
128. Position the EGR tube. Connect the fitting to the LH exhaust manifold.
^ Tighten to 39 Nm (29 lb-ft).
129. Connect the EGR tube fitting to the EGR system module.
^ Tighten to 39 Nm (29 lb-ft).
130. Connect the EGR system module and throttle position (TP) sensor electrical connectors.
131. Connect the fuel rail pressure and temperature sensor electrical connector and the vacuum tube.
132. Attach the B+ terminal to the generator and install the nut.
^ Tighten to 8 Nm (71 lb-in).
^ Attach the wiring retainer to the generator.
133. Connect the generator and throttle body (TB) electrical connectors.
134. Install the special tool to the RH cylinder head.
135. Install the special tool to the LH cylinder head.
136. Using the special tools, remove the engine from the engine stand.
137. NOTE: Be sure the crankshaft rear sealing surface is clean and free from any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep.
Lubricate the crankshaft rear oil seal with clean engine oil.
138. Install the special tools.
139. Position the crankshaft rear oil seal.
140. Using the special tool, install the crankshaft rear oil seal.
141. Install the spacer plate and if equipped, the flexplate-to-crankshaft spacer.
142. NOTE: Special bolts are used for flexplate and flywheel installation. Do not use standard bolts.
Install the flexplate or flywheel.
^ Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 13 Nm (10 lb-ft).
^ Stage 2: Tighten to 50 Nm (37 lb-ft).
^ Stage 3: Tighten an additional 90 degrees.
