Part 4
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Timing Drive Components - Roller Timing Chain
NOTE: Stamped steel RH timing chain guide shown, composite guide similar.
Timing Drive Components - Inverted Tooth Timing Chain
Lower Engine Block (View 1)
Lower Engine Block (View 2)
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information.
103. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.
- Tighten to 14 Nm (124 lb-in).
104. Using a new gasket, install the oil filter adapter and 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
105. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
106. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
107. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
108. 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.
Using new gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
109. Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
110. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
- Remove the retaining clips and separate the fuel injectors from the fuel rail.
- Remove and discard the O-ring seals.
- Install new O-ring seals and lubricate with clean engine oil.
- Install the fuel injectors and the retaining clips onto the fuel rail.
111. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
112. Install the coolant bypass hose to the thermostat housing.
113. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
114. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold support bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).
115. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
116. Install the cover and the pin-type retainer.
117. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
118. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
- Tighten the block heater to 40 Nm (30 lb-ft).
119. Install 6 new RH exhaust studs.
- Tighten to 12 Nm (106 lb-in).
120. NOTICE: 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 (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
121. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
Front Wheel Drive (FWD) vehicles
122. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
All engines
123. Install 6 new LH exhaust studs.
- Tighten to 12 Nm (106 lb-in).
124. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts.
- Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft).
- Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
125. Install the LH exhaust heat shield and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
126. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
127. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
128. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).
129. Install the PSP tube bracket and nut to the RH valve cover stud bolt.
- Tighten to 7 Nm (62 lb-in).
130. Install the PSP tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).
131. Install the stud, generator and the nut and the bolt.
- Tighten the generator stud to 12 Nm (106 lb-in).
- Tighten nut and bolt to 48 Nm (35 lb-ft).
132. Position the wiring harness onto the engine.
133. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
134. Connect the generator electrical connector.
135. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).
136. Connect the A/C compressor electrical connector.
- Attach the A/C compressor wiring harness retainer.
