Steps 81-116
Engine
Upper Engine
Timing Drive
Lower Engine
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. For additional information, refer to Engine System - General Information Procedures.
81. Install the Heated Oxygen Sensor (HO2S) electrical connector bracket and the nut.
- Tighten to 8 Nm (71 lb-in).
82. NOTE: Lubricate the O-ring seals with clean engine oil.
Install the VCT oil control solenoids and the 2 bolts.
- Tighten to 8 Nm (71 lb-in).
83. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 8 Nm (71 lb-in).
84. NOTE: Apply thread sealant to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.
- Tighten to 15 Nm (133 lb-in).
85. Install the crankcase vent oil separator and the bolts.
- Tighten to 9 Nm (80 lb-in).
86. Install the RH Knock Sensor (KS) at the 2 o'clock position and the LH KS at the 11 o'clock position and install the bolts.
- Tighten to 20 Nm (177 lb-in).
87. Install the thermostat and seal in the engine block.
88. Install the gasket, thermostat housing and the 4 bolts finger tight. Tighten the bolts in sequence shown in 2 stages.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
89. Install the oil cooler and the bolt.
- Tighten to 56 Nm (41 lb-ft).
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.
Inspect and install new intake manifold gaskets if necessary.
91. Install the intake manifold and the 7 bolts.
- Connect the PCV hose to the intake manifold.
- Tighten to 18 Nm (159 lb-in).
92. Attach the KS electrical connector to the intake manifold.
93. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.
94. Install the 4 fuel injectors and the 4 fuel injector clips into the fuel rail.
95. Install the fuel rail and fuel injectors as an assembly and install the 2 bolts.
- Tighten to 11 Nm (97 lb-in).
96. If equipped, position the block heater and finger-tighten the nut, making sure the block heater electrical connector points to the 8 o'clock position.
- Tighten the nut to 3 Nm (27 lb-in).
97. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator and tube and the screw.
- Tighten to 4 Nm (35 lb-in).
98. Install the LH engine lift eye and the 2 bolts.
- Tighten to 19 Nm (168 lb-in).
99. Install the ignition coil and coolant outlet assembly and the 4 bolts.
- Tighten to 19 Nm (168 lb-in).
100. Install the coolant outlet bracket, nut and the bolt.
- Tighten to 6 Nm (53 lb-in).
101. Connect the coolant return hose to the cylinder head.
- Attach the coolant tube to the fuel rail retainers.
102. Connect the coolant hose to the coolant outlet.
103. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
Install the 4 spark plug wires.
104. Install the Evaporative Emission (EVAP) canister purge valve and the bolt.
- Tighten to 9 Nm (80 lb-in).
105. Attach the EVAP tube and coolant tube to the coolant outlet bracket retainer.
106. Connect the brake booster vacuum tube to the intake manifold.
107. Connect the EVAP canister purge valve tube to the intake manifold.
108. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
Vehicles with automatic transaxle
109. Align the flexplate and crankshaft using the dowel pin location hole and install the new bolts finger tight.
110. Install the Flywheel Holding Tool.
111. Tighten the bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 80 degrees.
Vehicles with manual transaxle
112. Align the flywheel and crankshaft using the dowel pin location hole and install the new bolts finger tight.
113. Install the Flywheel Holding Tool.
114. Tighten the bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 80 degrees.
115. NOTICE: Be sure the clutch is installed correctly in the pressure plate. The side of the clutch marked gearbox side faces the pressure plate fingers. Failure to install the clutch plate will damage the clutch assembly during installation on the flywheel.
NOTICE: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent or damage may occur.
Position the clutch disc on the clutch pressure plate with the side of the clutch marked gearbox side facing the pressure plate fingers. Using a suitable clutch aligner, centralize the clutch disc to the clutch pressure plate.
116. NOTE: Use a clutch disc aligner (such as OTC(R) Clutch Alignment Tool Set 4528 or equivalent).
Using a clutch disc aligner, position the clutch disc and clutch pressure plate on the flywheel. Install the 6 new clutch pressure plate-to-flywheel bolts.
- Tighten the bolts evenly two turns at a time in the pattern shown.
- Tighten to 29 Nm (21 lb-ft).
