Steps 61-123

61. NOTE: LH shown, RH similar.

Install the 2 exhaust manifold heat shields and 8 bolts.
^ Tighten to 3 Nm (27 inch lbs.).





62. NOTE: LH shown, RH similar.

Install the 2 exhaust manifold heat shield stud bolts.
^ Tighten to 50 Nm (37 ft. lbs.).





63. Install a new gasket, EGR tube and 2 nuts.
^ Tighten to 20 Nm (15 ft. lbs.).





64. NOTE: RH shown, LH similar.

Install new valve cover gaskets.





65. NOTE: RH shown, LH similar.

NOTE: If the valve covers are not secured within 4 minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply 4 beads of silicone gasket and sealant as shown.





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





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

68. Install a new gasket and the coolant pump.
^ Install the 5 bolts and tighten in 2 stages.
- Stage 1: Tighten to 8 Nm (71 inch lbs.).
- Stage 2: Tighten an additional 90 degrees.





69. Install the throttle body coolant hose.





70. Install a new O-ring seal, the coolant inlet housing and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





71. Install new O-ring seals, the coolant bypass housing and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





72. Install new intake manifold gaskets.





73. Install the intake manifold, the 7 bolts and the 3 studs.
^ Tighten the 7 bolts and the 3 studs in the sequence shown to 20 Nm (15 ft. lbs.).





74. Connect the 2 throttle body coolant hoses.





75. 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 16 new O-ring seals onto the fuel injectors.
^ Lubricate the O-ring seals with clean engine oil.
^ Install the fuel injectors and clips onto the fuel rail.





76. Install the fuel rail and injector assembly and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





77. NOTE: RH shown, LH similar.

Install the 2 radio interference ignition capacitors and nuts.
^ Tighten to 10 Nm (89 inch lbs.).





78. Install a new gasket, the Exhaust Gas Recirculation (EGR) system module and bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
^ Tighten the EGR tube nut to 40 Nm (30 ft. lbs.).





79. Install the starter motor and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





80. Install the generator bracket and 4 bolts.
^ Tighten to 42 Nm (31 ft. lbs.).





81. Install the generator, the bolt and the 2 nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





82. Install the crankcase vent tube.





83. Install the 8 ignition coils and bolts.
^ Tighten to 5 Nm (44 inch lbs.).





84. CAUTION: Make sure the O-ring seal remains in position and does not roll up the indicator tube during installation.

Install a new O-ring seal, oil level indicator tube and nut.
^ Lubricate the O-ring seal with clean engine oil.
^ Tighten to 6 Nm (53 inch lbs.).





85. Install the Crankshaft Position (CKP) sensor and bolt.
^ Tighten to 10 Nm (89 inch lbs.).

86. Position the engine wiring harness onto the engine.





87. Attach the Heated Oxygen Sensor (HO2S) electrical connectors onto the brackets.





88. Connect the generator electrical connector and wiring harness retainers.





89. Connect the wiring harness retainers to the RH valve cover.





90. Connect the CKP sensor electrical connector and wiring harness retainers.





91. Attach the wiring harness onto the front cover.





92. Connect the wiring harness retainers to the LH valve cover.





93. Install the power steering bracket and 5 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





94. NOTE: RH shown, LH similar.

Connect the 2 VCT sensor electrical connectors.





95. Connect the KS and CMP sensor electrical connectors.
^ Attach the pin type retainers.





96. NOTE: LH shown, RH similar.

Connect the 8 fuel injectors and the 2 radio interference capacitor electrical connectors





97. NOTE: RH shown, LH similar.

Install the 2 engine appearance cover brackets and the 4 nuts.
^ Tighten to 6 Nm (53 inch lbs.).





98. Attach the vacuum hose retainers onto the LH engine appearance cover support bracket.





99. NOTE: LH shown, RH similar.

Connect the engine wiring harness retainers to the engine appearance cover support brackets.





100. Connect the 8 ignition coil electrical connectors





101. NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.

Lift up the wire harness and apply a 12.7 mm (0.5 inch) bead of silicone sealer in the notch of the valve cover.





102. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.





103. Install the ignition coil covers.
^ Tighten to 10 Nm (89 inch lbs.).





104. Install the vacuum harness.





105. Connect the coolant vent hose to the coolant outlet.





106. Connect the EGR system module electrical connector.





107. Connect the fuel rail temperature sensor electrical connector.





108. Connect the Evaporative emissions (EVAP) tube.





109. Connect the electronic throttle body electrical connector.





110. Connect the fuel pressure sensor electrical connector.





111. Connect the Throttle Position (TP) sensor electrical connector.





112. Using the special tool, install the coolant pump pulley and 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





113. Remove the bolt and the accessory drive belt tensioner.
^ Tighten to 25 Nm (18 ft. lbs.).





114. Install new O-ring seals, the oil filter adapter and 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

115. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

NOTE: Lubricate the gasket with clean engine oil.

Position the new oil cooler, new gasket and install the bolt.
^ Rotate the cooler clockwise until the locating pin hits the stop.
^ Tighten the bolt to 60 Nm (44 ft. lbs.).





116. NOTE: Lubricate the gasket with clean engine oil.

Install a new oil filter and gasket until the seal makes contact.
^ Using an oil filter strap wrench, tighten filter an additional 270 degrees.





117. Connect the oil pressure and oil temperature sensor electrical connectors.
118. Install the engine block drain plug.
^ Tighten to 50 Nm (37 ft. lbs.).





119. Install the LH engine mount bracket, stud bolt and 3 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).





120. Install the RH engine mount bracket, stud bolt and 3 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).





121. Install the special tool.





122. Install the special tool.
123. Install the engine lifting equipment and remove the engine from the stand.