Part 2

Engine continued

66. NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, install a new crankshaft front oil seal.





67. CAUTION: 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.





68. CAUTION: Only hand-tighten the 6 mm (0.23 inch) 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 (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.





69. CAUTION: The crankshaft must remain in the 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 special tool and the bolt should be installed using hand tools only.

CAUTION: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.).
^ Stage 2: Tighten an additional 90° (1/4 turn).





70. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





71. Remove the special tool.





72. Remove the special tool.





73. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.
74. Install the special tool.





75. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the special tool.





76. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, the engine valve timing must be corrected.





77. Using the special tool, check the position of the camshafts.
^ If it is not possible to install the special tool, the engine valve timing must be corrected.





78. Remove the special tool.





79. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.





80. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 Nm (62 inch lbs.).





81. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





82. Remove the special tool.





83. Install the engine plug bolt.
^ Tighten to 20 Nm (15 ft. lbs.).





84. CAUTION: 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 cleaner.

85. Apply silicone gasket and sealant to the locations shown.





86. 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 cleaner.

Install the valve cover.
^ Tighten the 14 bolts in the sequence shown to 10 Nm (89 inch lbs.).





87. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install a new cylinder head temperature (CHT) sensor and the spark plugs.
^ Tighten the CHT sensor to 12 Nm (9 ft. lbs.).
^ Tighten the spark plugs to 12 Nm (9 ft. lbs.).





88. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 coil-on-plugs, 4 bolts and the crankcase vent tube.
^ Tighten to 10 Nm (89 inch lbs.).





89. If equipped, install the block heater.
^ Tighten to 40 Nm (30 ft. lbs.).





90. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator and the KS.
^ Tighten the 8 oil separator bolts to 10 Nm (89 inch lbs.).
^ Tighten the KS to 20 Nm (15 ft. lbs.).





91. Install the coolant bypass hose.





92. Using a new gasket, install the coolant bypass and 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





93. Connect the coolant bypass hose.





94. Install the coolant hose.





95. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.





96. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





97. 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.





98. Install the fuel rail with the fuel injectors and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





99. Connect the fuel charging wiring harness.
^ Connect the fuel rail pressure and temperature sensor electrical connector.
^ Connect the 4 fuel injector electrical connectors.
^ Attach the wiring harness retainers.





100. Connect the wiring harness retainers to the valve cover studs.





101. Install the radio interference capacitor bracket and bolt.
^ Tighten to 10 Nm (89 inch lbs.).





102. Install the EGR tube.
^ Tighten to 55 Nm (41 ft. lbs.).





103. Inspect and install new intake manifold gaskets if necessary.

104. 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 (PCV) hose.





2.3L engines

105. NOTE: Be sure to install the bolts in the previously marked locations.

Install the intake manifold and the 7 mounting bolts.
^ Tighten to 18 Nm (13 ft. lbs.).





106. NOTE: Lubricate the O-ring with clean engine oil.

Install the oil level indicator tube assembly and 2 bolts.





107. Connect the swirl valve electrical connectors and pin-type retainers.





2.0L engines

108. NOTE: Be sure to install the bolts in the previously marked locations.

Install the intake manifold and the 7 mounting bolts.
^ Tighten to 18 Nm (13 ft. lbs.).