Engine Mechanical - 3.0L: Overhaul Mazda Tribute II

Disassembly

All vehicles

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Scheme 558

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Scheme 566

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Scheme 589

Scheme 590

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Scheme 592

Scheme 593

1. Remove the bolts and the flexplate.
2. Remove the engine-to-transaxle separator plate.
3. Using the special tools, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
6. Disconnect the electronic throttle control electrical connector.
7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
9. Detach the wiring harness retainer from the upper intake manifold.
10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
11. Disconnect the RH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers. Front wheel drive (FWD) vehicles
12. Disconnect the RH heated oxygen sensor (HO2S) electrical connector. All vehicles
13. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
14. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
15. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
16. Disconnect the fuel injector wiring harness electrical connector.
17. Disconnect the LH VCT electrical connector.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
19. Disconnect the LH HO2S electrical connector.
20. Disconnect the 3 LH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers.
21. Remove the nut and the B+ wire from the generator.
22. Detach the 2 wiring harness retainers. Remove the B+ harness from the engine. Front wheel drive (FWD) vehicles
23. Remove the EGR tube fitting from the EGR valve. All vehicles
24. Remove the 2 upper intake manifold bracket bolts (1 shown in the figure).
25. Remove the 7 bolts and the upper intake manifold. Remove and discard the gaskets.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.
28. Remove the 6 bolts and the 6 coil-on-plugs. NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal. NOTE: LH shown in the figure, RH similar. FWD vehicles
29. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
30. Remove the 3 bolts and the RH heat shield.
31. Remove the 3 nuts and the RH catalytic converter. Discard the nuts and gasket.
32. Remove the 6 RH exhaust manifold nuts and the manifold. Discard the nuts and gasket.
33. Remove and discard the 6 RH exhaust manifold studs. All vehicles
34. Remove the bolt, 2 nuts and the generator.
35. Remove the 3 bolts and the A/C compressor bracket.
36. Remove the 3 bolts and the LH heat shield.
37. Remove the stud bolt and the oil level indicator and tube. Remove and discard the O-ring seal.
38. Remove the 6 nuts, the LH catalytic converter and the gasket. Discard the gasket and nuts.
39. Remove and discard the 6 LH exhaust manifold studs.
40. Remove the EOP switch and, if equipped, the block heater.
41. Remove and discard the oil filter.
42. Position the Stretchy Belt Remover under the coolant pump belt as shown in the figure.
43. With the help of a assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown in the figure. NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 152 mm (5.984 in).
44. Remove the coolant pump belt. Fold the Stretchy Belt Remover over the top of the coolant pump belt. In one quick motion, pull the Stretchy Belt Remover up and toward the RH front of the vehicle removing the coolant pump belt.
45. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
46. Remove the 5 coolant pump housing bolts.
47. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
48. Remove the nut and the radio interference capacitor.
49. Remove the bolts and the RH valve cover. Discard the gasket.
50. Remove the bolts and the LH valve cover. Discard the gasket.
51. Remove the 15 bolts and the oil pan. Discard the gasket.
52. Remove the 2 bolts and the oil pump screen and pickup tube.
53. Remove and discard the O-ring seal.
54. Remove the oil pan baffle. Remove the 4 M6 oil pan baffle nuts. Remove the 4 M8 oil pan baffle nuts.
55. Remove the 3 bolts and the accessory drive belt tensioner.
56. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
57. Using the 3-Jaw Puller, remove the crankshaft pulley.
58. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
59. Remove the 2 bolts and the LH VCT. NOTE: Note the position of the alignment dowel on the engine front cover.
60. Remove the 2 bolts and the RH VCT. NOTE: Note the position of the alignment dowel on the engine front cover.
61. Remove the 14 bolts, 2 stud bolts and the engine front cover. Discard the gaskets. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant. NOTE: Note the location of all bolts and stud bolts for installation.
62. Remove the LH and RH spark plugs. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: LH shown in the figure, RH similar.
63. Remove the ignition pulse wheel. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the key-way in the slot stamped "30RFF" (orange in color).
64. Install the crankshaft pulley bolt and washer.
65. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
66. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
67. Verify that the RH camshafts are in the neutral position.
68. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
69. Remove the 2 bolts and the RH timing chain guide. Remove the RH timing chain from the engine.
70. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
71. Verify the LH camshafts are in the neutral position.
72. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
73. Remove the 2 bolts and the LH timing chain guide. Remove the LH timing chain from the engine.
74. Remove the crankshaft pulley bolt and the crankshaft sprocket.
75. Remove the 4 bolts in the sequence shown in the figure. Remove the oil pump.
76. Using the Oil Seal Remover, remove the camshaft oil seal and discard. CAUTION: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
77. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
78. Verify the LH camshafts are in the neutral position. CAUTION: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
79. Remove the 3 bolts and the LH camshaft Phaser and sprocket. CAUTION: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur. NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
80. Remove and discard the VCT system oil filter screen from the LH camshaft.
81. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration. CAUTION: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
82. Loosen the bolts evenly in the sequence shown in the figure. Remove the camshaft bearing thrust caps (1L and 5L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head. CAUTION: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage. NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
83. Verify the RH camshafts are in the neutral position. CAUTION: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
84. Remove the 3 bolts and the RH camshaft phaser and sprocket. CAUTION: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur. NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
85. Remove and discard the VCT system oil filter screen from the RH camshaft.
86. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration. CAUTION: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
87. Loosen the bolts evenly in the sequence shown in the figure. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head. CAUTION: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur. NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
88. Remove the LH and RH camshaft roller followers. Mark the location of the roller followers, using a permanent-type marker. CAUTION: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur. NOTE: RH shown in the figure, LH similar.
89. Remove the hydraulic lash adjusters. CAUTION: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
90. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the bolts and the gaskets. NOTE: RH shown in the figure, LH similar.
91. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
92. Remove the bolts and the oil separator cover. Discard the gasket.
93. Remove the crankshaft key.

Scheme 594

Scheme 595

1. For additional information, see the procedures in this service information.

Scheme 596

Scheme 597

1. Using the special tools, remove the keys, retainer, and spring.
2. Remove the valve from the cylinder head.
3. Remove the valve stem seal.

Scheme 598

1. Using the special tool, install the valve stem seal.
2. Install the valve.
3. Using the special tools, install the valve spring, retainer and key.

Assembly

All vehicles

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1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the crankcase cover, a new gasket and the bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
3. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in the figure in 6 stages. Stage 1: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 2: Tighten 90 N.m {9.2 kgf.m, 66 ft.lbf}. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees. NOTE: LH shown in the figure, RH similar.
4. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil. CAUTION: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers. CAUTION: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur. NOTE: RH shown in the figure, LH similar.
8. Install the new LH and RH oil filter screens in the intake camshafts. NOTE: RH shown in the figure, LH similar.
9. Position the camshaft phaser and sprockets onto the intake camshafts. Install the 3 bolts finger-tight.
10. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown in the figure.
11. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
12. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
13. Tighten the LH camshaft bearing cap bolts in the sequence shown in the figure in 2 stages. Stage 1: Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
14. Lubricate the bearing surfaces of the RH camshaft thrust bearing caps with clean engine oil and install the bearing caps. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 N.m {1.8 kgf.m, 159 in.lbf}. CAUTION: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur. NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
15. Install the camshaft oil seal retainer and the 2 bolts. Tighten in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
16. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
17. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown in the figure.
18. Install the camshaft bearing caps. Loosely install the bolts. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur. NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
19. Install the camshaft bearing thrust caps. Loosely install the bolts. NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
20. Tighten the RH camshaft bearing cap bolts in the sequence shown in the figure in 2 stages. Stage 1: Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
21. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 N.m {1.8 kgf.m, 159 in.lbf}. CAUTION: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur. NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
22. Position the oil pump and install the bolts. Tighten in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}.
23. Remove the crankshaft pulley bolt.
24. Install the crankshaft sprockets with the timing marks out.
25. Position the chain tensioner in a soft-jawed vise. NOTE: LH shown in the figure, RH similar.
26. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick. NOTE: LH shown in the figure, RH similar.
27. Slowly compress the timing chain tensioner. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
28. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
29. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
30. Install the RH timing chain tensioner arm and the RH timing chain tensioner. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
31. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
32. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
33. Verify that the RH camshafts are correctly positioned.
34. Install the RH timing chain and chain guide and install the bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
35. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
36. Remove the LH and RH timing chain tensioner piston retaining wires.
37. Rotate the crankshaft counterclockwise 120 degrees to TDC.
38. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
39. Remove the crankshaft pulley bolt and washer.
40. Install the ignition pulse wheel. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the key-way in the slot stamped "30RFF" only (orange in color).
41. Install the LH and RH spark plugs. Tighten to 15 N.m {1.5 kgf.m, 133 in.lbf}. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
42. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface prep and install new gaskets. 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. CAUTION: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
43. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces. NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant. NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
44. Position the front cover and install the bolts and stud bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. NOTE: Fasteners 4 and 13 are stud bolts.
45. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Note the position of the alignment dowel on the engine front cover.
46. Install the 2 bolts and the RH VCT solenoid. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
47. Apply clean engine oil to the seal lip and seal bore before installing the seal. NOTE: Clean all sealing surfaces with metal surface prep.
48. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
49. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot. NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant. NOTE: Sealing surfaces must be free of dirt and oil. NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
50. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley. NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
51. Install the bolt and washer. Tighten the bolt in 4 stages: Stage 1: Tighten to 120 N.m {12.0 kgf.m, 89 ft.lbf}. Stage 2: Loosen one full turn. Stage 3: Tighten to 50 N.m {5.0 kgf.m, 37 ft.lbf}. Stage 4: Tighten an additional 90 degrees.
52. Install the belt tensioner and the 3 bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
53. Install the 8 nuts and the oil pan baffle. Tighten the 4 M6 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf}. Stage 2: Tighten an additional 45 degrees. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 15 N.m {1.5 kgf.m, 133 in.lbf}. Stage 2: Tighten an additional 45 degrees.
54. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate the O-ring seal with clean engine oil.
55. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the 2 bolts and tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
56. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints. NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application. NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
57. Position the LH valve cover and install the bolts and stud bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
58. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.
59. Position the RH valve cover and install the bolts and stud bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Install a new valve cover gasket.
60. Install the radio interference capacitor and the nut. To install, tighten to 6 N.m {0.6 kgf.m, 53 in.lbf}.
61. Position the coolant pump housing and attach the coolant hose. To install, tighten to 7 N.m {0.7 kgf.m, 62 in.lbf}.
62. Install the 5 coolant pump housing bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
63. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
64. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools. NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).
65. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
66. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley. CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
67. Lubricate the O-ring seal with clean engine oil and install the oil filter. Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf} and then rotate an additional 180 degrees.
68. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater. Tighten the EOP switch to 14 N.m {1.4 kgf.m, 124 in.lbf} Tighten the block heater to 21 N.m {2.1 kgf.m, 15 ft.lbf}.
69. Install 6 new LH catalytic converter studs. To install, tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
70. Install a new gasket and the LH catalytic converter and 6 new nuts. Tighten in the sequence shown in the figure to 20 N.m {2.0 kgf.m, 177 in.lbf}.
71. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
72. Position the oil level indicator and tube and install the stud bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
73. Install the 3 bolts and the LH heat shield. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
74. Install the 3 bolts and the A/C compressor bracket. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
75. Position the generator and install the bolt and 2 nuts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. FWD vehicles
76. Install 6 new RH exhaust manifold studs. Tighten to 12 N.m {1.2 kgf.m, 106 ft.lbf}.
77. Install a new gasket and the RH exhaust manifold and new nuts. Stage 1: Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}. Stage 2: Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
78. Install a new gasket and the RH catalytic converter and the 3 new nuts. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}.
79. Install the 3 bolts and the RH heat shield. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
80. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
81. Install the 6 coil-on-plugs and the bolts. To install, tighten to 6 N.m {0.6 kgf.m, 53 in.lbf}. NOTE: LH shown in the figure, RH similar. NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
82. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
83. 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.
84. Install the 4 bolts and the fuel rail and injectors assembly. Tighten in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}.
85. Position the upper intake manifold and install the 7 bolts. Tighten the bolts in 2 stages in the sequence shown in the figure. Stage 1: Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. Stage 2: Tighten an additional 45 degrees. NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
86. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown in the figure), then tighten all the bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. FWD vehicles
87. Install the EGR tube fitting in the EGR valve. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}. All vehicles
88. Position and attach the 3 B+ wiring harness retainers.
89. Install the B+ wire and nut on the generator. Tighten to 8 N.m {8.0 kgf.m, 71 in.lbf}.
90. Connect the 3 LH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers.
91. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
92. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
93. Connect the LH VCT electrical connector.
94. Connect the fuel injector wiring harness electrical connector.
95. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
96. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
97. Connect the RH VCT electrical connector.
98. Connect the RH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers. FWD vehicles
99. Connect the RH HO2S electrical connector. All vehicles
100. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
101. Attach the wiring harness retainer to the upper intake manifold.
102. Connect the EGR regulator electrical connector and attach the wiring retainer.
103. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
104. Connect the electronic throttle control electrical connector.
105. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
106. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.
107. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal. NOTE: Lubricate the seal lips and seal bore with clean engine oil before installing.
108. Install the engine-to-transaxle separator plate.
109. Position the flexplate and install the bolts. To install, tighten to 80 N.m {8.2 kgf.m, 59 ft.lbf}.