Steps 51-100
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.
51. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).
52. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 Nm (53 lb-ft).
53. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean and inspect the mounting surfaces of the engine and the front cover.
54. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
55. Install the engine front cover. Tighten the 22 bolts in the sequence shown to the following specifications:
- Tighten the 8-mm bolts to 10 Nm (89 lb-in).
- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
56. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
57. NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
58. NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
59. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees (one-fourth turn).
60. Remove the 6 mm x 18 mm bolt.
61. Remove the Crankshaft TDC Timing Peg.
62. Remove the Camshaft Alignment Plate.
63. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turn.
64. Install the Crankshaft TDC Timing Peg.
65. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
66. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.
67. Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
68. Remove the Camshaft Alignment Plate.
69. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
70. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
- Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
71. Remove the 6 mm x 18 mm bolt.
72. Remove the Crankshaft TDC Timing Peg.
73. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
74. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean the valve cover gasket surface with metal surface prep.
75. Apply silicone gasket and sealant to the locations shown.
76. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.
Install the valve cover.
- Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).
77. NOTICE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
- Tighten the CHT sensor to 12 Nm (106 lb-in).
- Tighten the spark plugs to 12 Nm (106 lb-in).
78. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 ignition coil-on-plugs and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
79. If equipped, install the engine block heater.
- Tighten to 40 Nm (30 lb-ft).
80. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
81. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS and the bolt.
- Tighten to 20 Nm (177 lb-in).
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. 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.
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 (159 lb-in).
94. Install the lower intake manifold bolt.
- Tighten to 18 Nm (159 lb-in).
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. NOTICE: 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.
