Part 4
Engine
Assembly
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. Connect the EGR valve coolant hose.
88. Install the radio interference capacitor bracket and bolt.
^ Tighten to 10 Nm (89 lb-in).
89. Install the EGR tube.
^ Tighten to 55 Nm (41 lb-ft).
90. Inspect and install new intake manifold gaskets if necessary.
91. Position the intake manifold and connect the PCV hose.
92. 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.
93. Install the 5 intake manifold mounting bolts.
^ Tighten all 7 bolts to 18 Nm (13 lb-ft).
94. Install the lower intake manifold bolt.
^ Tighten to 18 Nm (13 lb-ft).
95. NOTE: Lubricate the new O-ring with clean engine oil.
Using a new O-ring seal, install the oil level indicator tube assembly and the bolt.
^ Tighten to 10 Nm (89 lb-in).
96. Connect the EGR valve electrical connector and if equipped, connect the swirl control valve sensor electrical connector.
97. If equipped, connect the swirl control valve solenoid electrical connector.
98. Connect the manifold absolute pressure (MAP) electrical connector.
99. Connect the KS electrical connector and pin-type retainer.
100. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
Install new fuel injector O-rings.
^ Separate the fuel injectors from the fuel rail.
^ Remove and discard the fuel injector O-rings.
^ Install new O-rings. and lubricate with clean engine oil.
^ Install the fuel injectors onto the fuel rail.
101. Install the fuel rail with the fuel injectors and the 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).
102. Connect the 4 fuel injector electrical connectors and attach the wiring harness retainers to valve cover stud bolts and intake manifold.
103. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
104. Connect the 4 coil-on-plug and camshaft position (CMP) sensor electrical connectors.
105. NOTE: Clean the gasket mating surfaces with metal surface prep.
Using a new gasket, install the oil filter adapter and the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).
106. Connect the engine oil pressure (EOP) switch electrical connector.
107. Connect the heater hose and lower radiator hose to the thermostat housing.
108. NOTE: Clean the coolant pump mating surface with metal surface prep.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
Position the coolant pump and install the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).
109. Install the coolant pump pulley and 3 bolts.
^ Tighten to 20 Nm (15 lb-ft).
110. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 lb-ft).
111. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
112. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 lb-ft).
^ Stage 2: Tighten to 80 Nm (50 lb-ft).
^ Stage 3: Tighten to 112 Nm (83 lb-ft).
Engines equipped with a manual transaxle
113. Lubricate the transaxle input shaft pilot bearing with front axle grease.
114. Using the special tool, position the clutch disc on the flywheel.
115. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the 7 bolts. Tighten the bolts in a star pattern sequence to 27 Nm (20 lb ft).
