Part 2 of 2
41. Install the water pump.
42. Install the water pump pulley.
43. Install the fuel injection supply manifold and the ground strap.
44. Install the left motor mount.
Note:
^ The knock sensor must not touch the engine vent cover.
45. Install the engine vent cover and the knock sensor (KS).
Note:
^ Clean the thermostat housing gasket surface with metal surface cleaner.
46. Install a new gasket and the thermostat housing.
47. Install the bypass hose and the clamp.
48. Install the ignition coil.
Note:
^ Apply silicone dielectric compound to the inside of the spark plug boots.
49. Connect the spark plug wires to the spark plugs.
50. Install the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
51. Connect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
52. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.
53. Install the intake manifold.
54. Attach the vacuum line to the intake manifold. Secure the fuel line clip to the intake manifold.
55. Install the EGR tube.
^ Install the EGR tube bracket to the intake manifold.
^ Connect the EGR tube to the cylinder head.
56. Connect the EGR tube to the intake manifold.
57. Install the engine wiring harness connector bracket.
58. Attach the engine wiring harness pin-type retainers to the intake manifold.
59. Connect the CMP sensor electrical connector and the PCV hose.
60. Connect the following electrical connectors:
^ swirl control valve.
^ knock sensor.
^ electric thermostat.
61. Connect the CKP sensor and wiring pin-type retainers.
62. Connect the swirl control valve electrical connector.
63. Connect the following electrical connectors:
^ manifold absolute pressure (MAP) sensor.
^ throttle position (TP) sensor.
^ idle air control (IAC) valve.
64. Install the power steering pump assembly.
Note:
^ Clean the EGR valve gasket surface with metal surface cleaner.
65. Install a new gasket and the EGR valve. Connect the EGR electrical connector.
Note:
^ Clean the water outlet tube gasket surface with metal surface cleaner.
66. Install a new gasket and the water outlet tube.
^ Tighten the bolts.
^ Connect the coolant hose.
^ Connect the engine coolant temperature (ECT) sender electrical connector.
67. Install the block heater (if equipped).
68. Install the exhaust manifold and gasket.
69. Install the coolant tube assembly.
70. Connect the following:
^ coolant hose to the thermostat.
^ coolant hose to EGR tube.
71. Install the right motor mount.
72. Install the accessory bracket.
73. Install the A/C compressor.
Note:
^ Lubricate the O-ring seal with antifreeze.
74. Install the water outlet tube.
Note:
^ Lubricate the O-ring seal with clean engine oil.
75. Install the engine oil level indicator assembly.
76. Install the drive belt.
77. Using the Spreader Bar and the Floor Crane, remove the engine from the engine stand.
78. Install the flywheel or flexplate and the bolts. Tighten the bolts in the sequence shown in three stages.
^ Stage 1: Tighten the bolts to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten the bolts to 80 Nm (59 ft. lbs.).
^ Stage 3: Tighten the bolts to 112 Nm (83 ft. lbs.).
79. For vehicles with manual transmission, lubricate the transmission input shaft pilot bearing with front axle grease.
80. For vehicles with a manual transmission, adjust the clutch pressure plate.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
81. Using the special tool or equivalent shop tool, position the clutch disc on the flywheel.
Note:
^ If reusing the clutch pressure plate and flywheel, align the marks made during removal.
82. Position the clutch pressure plate and install the bolts. Tighten the bolts in the star pattern sequence.
^ Remove the Clutch Disc Aligner.