Part 2
40. Using the special tool, install the crankshaft pulley.
41. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
Install the crankshaft pulley and tighten the bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen the bolt one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tight an additional 90°.
42. Install the water pump pulley.
RH Cylinder Head
43. Install the RH exhaust manifold.
- Install a new RH exhaust manifold gasket.
- Install the RH exhaust manifold.
- Tighten the nuts in the sequence shown.
LH Cylinder Head
44. Inspect O-ring seals and install O-ring seals as necessary.
45. Install the coolant bypass tube.
1. Install the bypass tube.
2. Install the nut and tighten to 25 Nm (18 lb-ft).
46. NOTE: Lubricate the O-ring with clean engine oil.
- Install the oil level indicator tube.
- Install a new O-ring on the oil level indictor tube.
47. Install the LH exhaust manifold.
- Install a new LH exhaust manifold gasket.
- Install the LH exhaust manifold.
- Tighten the nuts in the sequence shown.
Both Cylinder Heads
48. Install the knock sensor harness.
1. LH knock sensor connector.
2. RH knock sensor connector.
3. Engine control sensor wiring connector.
4. Fuel injector connector.
5. NC compressor connector.
6. Crankshaft position sensor connector.
49. Install the lower intake manifold (9424).
- Position the gaskets (9439).
Install the intake manifold and tighten the bolts in the sequence shown.
50. NOTE: Only three bolts are required for installation.
Install the power steering pump bolts.
- Position the power steering pump. Install the bolts.
51. Position the power steering reservoir and bracket, and install the bolts.
52. Install the generator.
53. Install the upper generator support bracket and water bypass tube.
- Install the upper generator support bracket.
- Inspect and install new 0-ring seals if necessary. Install the water bypass tube.
54. Install the accessory drive belt.
55. Connect the knock sensor jumper harness.
56. Install the eight ignition coils.
57. Connect the eight ignition coils (12029).
58. Connect the engine coolant temperature (ECT) sensor (12A648).
59. Connect the eight fuel injectors (9F593).
60. Install the RH ignition coil cover.
61. Install the LH ignition coil cover.
62. NOTE: The fastener at location five is a stud.
Install the gasket and the upper intake.
63. Connect the throttle position (TP) sensor (9B989).
64. Connect the idle air control (IAC) valve (9F715).
65. Connect the generator.
66. Connect the EGR vacuum regulator (EVR).
67. Connect the fuel pressure sensor.
68. Connect the EGR tube (9D477) to the exhaust manifold.
69. Connect the EGR tube to the EGR valve (9D460).
70. Install the PCV valve (6A666) and tube.
71. Connect the PCV valve tube to the upper intake manifold.
72. Install the RH engine mount bolts and install.
73. Install the special tools.
74. Remove the engine from the stand.
75. Install the engine/transmission spacer plate.
76. Install the flywheel. Tighten in the sequence shown.
77. NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil. Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.
Position the clutch disc on the flywheel.
- Using the special tool, align the clutch disc.
78. NOTE: If reusing the clutch pressure plate, align the plate using the marks made during removal.
Position the pressure plate and loosely install the bolts, then tighten in two stages in a cross pattern.
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 60°.
79. Install the engine. Service and Repair