Part 2
57. Apply silicone gasket and sealant to the locations shown.
58. NOTE: The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Install the valve cover.
- Tighten the bolts in the sequence shown.
59. NOTICE: Only use hand tools when installing the spark plugs, damage can occur to the cylinder head or spark plug.
Install the spark plugs.
60. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the coil-on-plugs and the crankcase vent tube.
61. If equipped, install the block heater.
62. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the crankcase vent oil separator and the KS.
63. Install the coolant bypass hose.
64. Using a new gasket, install the coolant bypass and bolts.
65. Connect the coolant bypass hose.
66. Install the coolant hose.
67. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
68. Connect the coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
69. Connect the Exhaust Gas Recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
70. Attach the wiring harness retainer.
71. 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.
72. Position the fuel rail spacers.
73. Install the fuel rail with the fuel injectors.
74. Connect the fuel charging wiring harness.
- Connect the fuel rail pressure and temperature sensor electrical connector.
- Connect the four fuel injector electrical connectors.
- Attach the wiring harness retainers.
75. Connect the wiring harness retainers to the valve cover studs.
76. Install the radio interference capacitor bracket and bolt.
77. Install the EGR tube.
78. Inspect and install new intake manifold gaskets if necessary.
79. 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 positive crankcase ventilation hose.
2.3L engines
80. NOTE: Be sure to install the bolts in the previously marked locations.
Install the intake manifold and the seven mounting bolts.
81. NOTE: Lubricate the O-ring with clean engine oil.
Install the oil level indicator tube assembly and bolts.
82. Connect the swirl valve electrical connectors and pin-type retainers.
2.0L engines
83. NOTE: Be sure to install the bolts in the previously marked locations.
Install the intake manifold and the seven mounting bolts.
84. NOTE: Lubricate the O-ring with clean engine oil.
Install the oil level indicator tube assembly and bolt.
85. Connect the swirl control valve electrical connector.
86. If equipped, connect the AIR vacuum supply hose.
All engines
87. Connect the Manifold Absolute Pressure (MAP) electrical connector.
88. Connect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
89. Attach the wiring harness pin-type retainer.
90. Connect the fuel rail pressure and temperature sensor vacuum hose.
91. Connect the Idle Air Control (IAC) valve electrical connector and wiring harness pin-type retainer.
92. Connect the Throttle Position (TP) sensor electrical connector and wiring harness pin-type retainer.
93. Install the lower intake bolt.
94. Connect the Knock Sensor (KS) electrical connector and pin-type retainer.
95. NOTE: Clean the gasket mating surfaces with metal surface cleaner.
Install the oil filter adapter with a new gasket.
96. Install a new oil filter.
97. Connect the oil pressure sensor electrical connector.
98. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
Install the thermostat housing and bolts.
99. Connect the heater hose to the thermostat housing.
100. NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
Position the coolant pump and install the bolts.
101. Install the coolant pump pulley and bolts.
102. If equipped, install the accessory drive belt idler pulley and bolt.
103. Install the accessory drive belt idler pulley and bolt.
104. Install the accessory drive belt tensioner and bolts.
105. Install the generator and bolts.
106. Install the wiring harness retainer and nut.
107. Connect the generator electrical connections, harness retainer and install the nut.
108. Install the generator heat shield and nuts.
109. Connect the CKP sensor and the wiring harness pin-type retainers.
110. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
111. Install the flexplate or flywheel and the bolts. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten to 50 Nm (37 ft. lbs.).
- Stage 2: Tighten to 80 Nm (59 ft. lbs.).
- Stage 3: Tighten to 112 Nm (83 ft. lbs.).
Engines equipped with a manual transmission
112. Lubricate the transaxle input shaft pilot bearing with front axle grease.
113. Using the special tool, position the clutch disc on the flywheel.
114. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
