Steps 101-115

Engine



















Lower Engine Block (View 1)











Lower Engine Block (View 2)











Front Engine Block











Cylinder Head











Intake Manifold









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

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.

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 (177 lb-in).





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 Clutch Disc Aligner, 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).