Part 2

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ENGINE ASSEMBLY - 2.5L

Part 2

Continued From Part 1 Part 1

CAUTION:Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshafts and the camshafts must be locked in place by the special tools, otherwise, severe engine damage may occur.

CAUTION: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.

46. Install the special tool.






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

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






48. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.

- If it is not possible to install the bolt, the engine valve timing must be corrected.

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






49. Install the special tool to check the position of the camshafts.

- If it is not possible to install the special tool, the engine valve timing must be corrected.






50. Remove the special tool.






51. Install a new crankshaft position (CKP) sensor and the 2 bolts.

- Do not tighten the bolts at this time.






52. Adjust the CKP sensor with the alignment tool.

- Tighten the 2 CKP bolts to 7 Nm {0.7 kgf-m, 62 in-lbf}.






53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.






54. Remove the special tool.






55. Install the engine plug bolt.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.

56. Clean the valve cover gasket surface with metal surface cleaner.

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.






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






58. Install the valve cover.

- Tighten the bolts in the sequence shown to 10 Nm {1.0 kgf-m, 89 in-lbf}.

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.






59. Install a new cylinder head temperature (CHT) sensor and the spark plugs.

- Tighten the CHT sensor to 12 Nm {1.2 kgf-m, 106 in-lbf}.

- Tighten the spark plugs to 12 Nm {1.2 kgf-m, 106 in-lbf}.

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






60. Install the coil-on-plugs, bolts and the crankcase vent tube.

- Tighten to 8 Nm {0.8 kgf-m, 71 in-lbf}.

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






61. Install the oil level indicator.

NOTE:Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.






62. If equipped, install the block heater.

- Tighten to 21 Nm {2.1 kgf-m, 15 ft-lbf}.






63. Install the crankcase vent oil separator and the 8 bolts.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.






64. Install the Knock Sensor (KS) and the bolt.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.

NOTE:The KS must not touch the crankcase vent oil separator.






65. Install the 2 coolant hoses.






66. Install the coolant hose.






67. Install the coolant hose.






68. Install the EGR tube.

- Tighten to 55 Nm {5.5 kgf-m, 41 ft-lbf}.






69. Position the intake manifold and connect the crankcase vent oil separator tube.






70. Install the intake manifold gaskets, intake manifold and the 8 bolts.

- Tighten to 18 Nm {1.8 kgf-m, 159 in-lbf}.






71. 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.

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.






72. Install the fuel rail with the fuel injectors and stud bolts.

- Tighten to 23 Nm {2.3 kgf-m, 17 ft-lbf}.






73. Install the radio capacitor and nut.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.






74. Install the fuel rail insulator.






75. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.






76. Connect the radio capacitor electrical connector.






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






78. Connect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.

79. Attach all the wiring harness retainer to the intake manifold.






80. Connect the KS and attach the 2 wiring harness retainers.






81. Connect the EGR valve electrical connector.






82. Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.






83. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.






84. Attach the wiring harness retainers to the LH side valve cover stud bolts.






85. Connect the crankcase vent hose to the valve cover.






86. Attach the wiring harness retainers to the RH side valve cover stud bolts.






87. Connect the VCT electrical connector.






88. If removed, install the capacitor and bolt.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.






89. Install the oil filter adapter with a new gasket.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

NOTE:Clean the gasket mating surfaces with metal surface prep.
NOTE:Spin on oil filter adapter shown, element oil filter adapter similar.






90. Connect the Engine Oil Pressure (EOP) switch electrical connector.






91. Install the coolant tube retainer to the intake manifold.






92. Install the thermostat housing and bolts.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

NOTE:Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.






93. Install the coolant pump and bolts.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

NOTE:Clean the coolant pump mating surface with metal surface prep.
NOTE:Lubricate the coolant pump O-ring with clean engine coolant.






94. Install the 3 coolant pump pulley and bolts.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.






95. Install the accessory drive belt idler pulley and bracket and the 2 bolts.

- Tighten to 25 Nm {2.0 kgf-m, 18 ft-lbf}.






96. Install the accessory drive belt idler pulley.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.






97. Install the accessory drive belt tensioner and the 2 bolts.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.






98. Install 7 new exhaust manifold studs in the cylinder head.

- Tighten to 17 Nm {1.7 kgf-m, 150 in-lbf}.

99. Install the new exhaust manifold gasket on the engine.






100. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages.

- Stage 1: Tighten to 48 Nm {4.8 kgf-m, 35 ft-lbf}.
- Stage 2: Tighten to 48 Nm {4.8 kgf-m, 35 ft-lbf}.

CAUTION:Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTE:Make sure to tighten the nuts in the sequence in 2 stages.






101. Install the heat shield and the 6 bolts.

- Tighten to Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.






102. Connect the Heated Oxygen Sensor (HO2S) electrical connector.






103. Install the generator, 2 nuts and 1 bolt.

- Tighten to Tighten to 47 Nm {4.7 kgf-m, 35 in-lbf}.






104. Connect the generator electrical connection and install the nut.

- Tighten to Tighten to 6 Nm {0.6 kgf-m, 53 in-lbf}.






105. Connect the generator electrical connection and attach the 2 wiring harness retainers.






106. Connect the CKP sensor electrical connector.

- Attach the wiring harness-to-engine retainer.

107. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.

Vehicles with automatic transaxles





1. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages.

- Stage 1: Tighten to 50 Nm {5.1 kgf-m, 37 ft-lbf}.
- Stage 2: Tighten to 80 Nm {8.2 kgf-m, 59 ft-lbf}.
- Stage 3: Tighten to 112 Nm {11.4 kgf-m, 83 ft-lbf}.

Vehicles with manual transaxles





1. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages.

- Stage 1: Tighten to 50 Nm {5.1 kgf-m, 37 ft-lbf}.
- Stage 2: Tighten to 80 Nm {8.2 kgf-m, 59 ft-lbf}.
- Stage 3: Tighten to 112 Nm {11.4 kgf-m, 83 ft-lbf}.






2. Lubricate the transaxle input shaft pilot bearing with front axle grease.






3. Using the special tool, position the clutch disc on the flywheel.

4. Position the clutch pressure plate and install the bolts.

- Tighten to 29 Nm {2.9 kgf-m, 21 ft-lbf} in a star pattern sequence.

NOTE:If reusing the clutch pressure plate and flywheel, align the marks made during removal.