Part 3
EngineAssembly (Steps 85-145)
85. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
Front wheel drive (FWD) vehicles
86. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).
87. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).
All vehicles
88. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
89. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
90. Install the LH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).
91. Install the 4 new LH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).
92. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
^ Tighten to 40 Nm (30 lb-ft).
93. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 lb-inch).
94. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).
95. Install the power steering pressure (PSP) tube bracket and bolt to the RH cylinder head.
^ Tighten to 10 Nm (89 lb-inch).
96. Install the PSP hose bracket nut.
^ Tighten to 9 Nm (80 lb-inch).
97. Attach the PSP hose retainer to the engine lifting eye.
98. Install the generator, the nut and the bolt.
^ Tighten to 48 Nm (35 lb-ft).
99. Using new O-ring seals, install the A/C manifold and the bolt.
^ Tighten to 25 Nm (18 lb-ft).
100. Position the wiring harness onto the engine.
101. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
102. Attach the wiring harness retainer to the generator.
103. Connect the generator electrical connector.
104. Connect the generator B+ cable and install the nut.
^ Tighten to 6 Nm (53 lb-inch).
105. Connect the A/C compressor electrical connector.
106. Connect the CKP sensor electrical connector.
107. Install the wiring harness grommet.
108. Install the wiring harness retainer stud bolt.
^ Tighten to 10 Nm (89 lb-inch).
109. Install the heat shield, the nut and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
110. Install the wiring harness retainer bolt on the rear of the LH cylinder head.
^ Tighten to 10 Nm (89 lb-inch).
111. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
112. Connect the LH camshaft VCT solenoid electrical connector.
113. Connect the 3 LH coil-on-plug electrical connectors.
114. Connect the LH HO2S electrical connector.
115. Connect the LH catalyst monitor sensor electrical connector.
116. Connect the LH CMP sensor electrical connector.
117. Connect the CHT sensor electrical connector.
118. Connect the 6 fuel injector electrical connectors (3 shown).
119. Connect the KS electrical connector.
120. Connect the RH CMP sensor electrical connector.
121. Connect the coolant bypass hose to the thermostat housing.
122. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
123. If equipped, connect the heated PCV valve electrical connector.
124. Connect the 3 RH coil-on-plug electrical connectors.
125. Connect the RH VCT solenoid electrical connector.
FWD vehicles
126. Connect the RH catalyst monitor sensor electrical connector.
All vehicles
127. Connect the PSP switch electrical connector.
128. Using new gaskets, install the upper intake manifold and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
129. Install the upper intake manifold short support bracket and the 2 bolts (one shown).
^ Tighten to 10 Nm (89 lb-inch).
130. If equipped, install the upper intake manifold long support bracket and the 2 bolts (one shown).
^ Tighten the upper bolt 10 Nm (89 lb-inch).
^ Tighten the lower bolt 24 Nm (18 lb-ft).
131. Install the RH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).
132. Connect the RH HO2S electrical connector.
133. Attach the wiring harness retainers to the upper intake manifold.
134. Connect the throttle body (TB) electrical connector.
135. Connect the PCV hose to the PCV valve.
136. If equipped, connect the heated PCV electrical connector.
137. If equipped, position the block heater wiring harness onto the engine.
^ Attach the block heater wiring harness retainer to the power steering reservoir hose and the PSP hose.
138. If equipped, connect the block heater electrical connector and install the heat shield.
139. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
140. Install the special tool on the LH cylinder head.
141. Using the special tools, remove the engine from the stand.
142. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
143. Using the special tools, install the new crankshaft rear seal.
144. Install the crankshaft sensor ring.
145. Install the flexplate and the 8 bolts.
^ Tighten to 80 Nm (59 lb-ft).
