- Install the cylinder head gasket.
- Install the cylinder head with the intake manifold and the exhaust manifold attached.
Caution: Refer to Fastener Caution in the Preface section.
- Install the cylinder head bolts.
- Tighten the cylinder head bolts gradually and in the sequence shown.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Use the
J 45059 or the
KM-470-B to tighten the bolts another 3 turns of 90 degrees.
- Connect the throttle cable at the throttle body and the intake manifold.
- Install the generator-to-intake manifold support bracket.
- Install the intake generator-to-manifold support bracket bolts.
Tighten
Tighten the bolt to the intake manifold to 22 N·m (16 lb ft).
- Install the intake manifold support bracket bolt to the generator.
Tighten
Tighten the bolt at the generator to 22 N·m (16 lb ft).
- Connect the surge tank coolant hose at the throttle body.
- Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket.
- Connect the fuel feed line at the fuel rail.
- Connect the fuel return line at the fuel rail.
- Connect all of the necessary vacuum hoses.
- Install the fuel rail assembly. Refer to
Fuel Injection Fuel Rail Assembly Replacement.
- Install the exhaust flex pipe retaining nuts at the exhaust manifold studs.
Tighten
Tighten the nuts to 35 N·m (26 lb ft).
- Install the rear timing belt cover.
- Install the rear timing belt cover bolts.
Tighten
Tighten the bolts to 7 N·m (62 lb in).
- Install the engine mount and the retaining bolts.
Tighten
Tighten the bolts to 45 N·m (33 lb ft).
- Install the timing belt automatic tensioner.
- Install the timing belt automatic tensioner bolt.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Install the timing belt idler pulleys.
- Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Install the camshaft gears with the timing marks at the front.
- Insert the guide pin of the intake camshaft into the IN bore.
- Insert the guide pin of the exhaust camshaft into the EX bore.
- Install the camshaft gears by counterholding on the hex of the camshaft with an open-ended wrench.
- Install the camshaft gear with a new bolt to the camshaft.
Tighten
Tighten the bolt to 50 N·m (37 lb ft). Turn the bolt another 60 degrees and 15 degrees using the angular torque gage.
- While holding the exhaust firmly in place, install the exhaust camshaft gear bolt.
Tighten
Tighten the bolt to 50 N·m (37 lb ft). Turn the bolt another 60 degrees and 15 degrees using the
J 45059 or the
KM-470-B
.
- Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover-to-cylinder head seal.
- Install the camshaft cover and the camshaft cover gasket.
- Install the camshaft cover washers.
- Install the camshaft cover bolts.
Tighten
Tighten the bolts to 8 N·m (71 lb in).
- Connect the ignition wires to the spark plugs.
- Install the spark plug cover.
- Install the spark plug cover bolts.
Tighten
Tighten the bolts to 8 N·m (71 lb in).
- Connect the breather tube to the camshaft cover.
- Align the timing marks on the camshaft gears to the notches on the camshaft cover, using the intake gear mark (1), for the intake gear and the exhaust gear mark (2) for the exhaust gear.
- Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
- Install the timing belt.
- Check and adjust the timing belt tension. Refer to
Timing Belt Inspection.
- Install the front timing belt cover.
- Install the front timing belt cover bolts.
Tighten
Tighten the bolts to 6 N·m (53 lb in).
- Install the crankshaft pulley.
- Install the crankshaft pulley bolts.
Tighten
Tighten the bolts to 12 N·m (106 lb in).
- Install the right engine mount bracket and retaining bolts. Refer to
Engine Mount Replacement.
Tighten
Tighten the bolts to 55 N·m (41 lb ft).
- Remove the
J 28467-B .
- Install the serpentine accessory drive belt. Refer to
Power Steering Pump Belt Replacement.
- Connect the upper radiator hose to the thermostat housing.
- Install the right front wheel well splash shield.
- Install the right front wheel. Refer to
Tire and Wheel Removal and Installation.
- Install the air cleaner housing.
- Install the air cleaner housing bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Connect the air cleaner outlet hose to the throttle body.
- Connect the breather tube to the camshaft cover.
- Connect the IAT sensor connector.
- Connect the CTS connector.
- Connect the ECT sensor connector.
- Connect the IAC valve connector.
- Connect the TP sensor connector
- Install the CCP and the EGR solenoid bracket bolt.
Tighten
Tighten the bolt to 5 N·m (44 lb in).
- Connect the DIS coil connector.
- Connect the O2S connector, if equipped.
- Connect the ECM ground terminal.
- Install the fuel pump fuse.
- Connect the negative battery ground cable.
- Refill the engine cooling system. Refer to
Cooling System Draining and Filling.