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I've taken my sweet time doing the timing belt and remachining the head on my 02 4dr Ex, and I am getting things all put back and I have a couple of extra parts that are starting to freak me out a bit.



The first was in a bag that I marked "Lower Timing Belt Cover". See pic above. It is about an inch and a half long. I had all four of the lower timing belt cover bolts with the timing belt cover, and they are installed, as is the crankshaft TDC sensor with the appropriate bolt. I can't figure out what this guy is for and I am afraid I am going to have to re-open everything up, including the crankshaft bolt

Hoping someone can help me identify it.

The second part was in a bag full of parts to reattach the intake manifold. There were three nuts and three bolts. Pretty sure the nuts go on the under side of the (beneath the pipes) of the intake to secure it to the head, and I believe two of the bolts go on top of the manifold just under the fuel rail and attach to the head with a little aluminum rectangular block. That leaves just this final bolt. It looks like a 12 mm (head) and again, about an inch and a half long. I am less worried about this one, cause I have more to do here and guessing I will eventually discover a need for it.

Really worried about the first one though.

Anyone know.

 
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Thinking I may have found where the first bolt goes. See attached picture. Still not sure what it is for. The bolt fits well in that hole, but doesn't seem to go in all the way, which means it must be used to fasten something to the block there. The hole is just to the left of the harmonic balancer on the block.

 
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Oil pump bolt?
Oh boy.
Depends on what you took apart.

Check pics here, look at the flat surface on the head where the manifold assembly sits and count bolt holes........ and look at the injector plate and count bolt holes. Remember some have studs sticking through and will take nuts.

Don't forget there were brackets at the bottom of the intake too.

 
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Oil pump? Hmm, maybe.... I still really cannot figure out this bolt. I thought it might have something to do with the alternator bracket, but doesn't appear to. Referring back to my picture, can anyone take a snap or point to a snap of how everything should look when put together right down there to the left of the harmonic balancer?

In regards to the second bolt, it is the same as the bolt 32 in the picture you attached. I see one in the diagram that looks like it goes into the back are of the intake manifold. Going to investigate that area now.

The first bolt is the real troubling one though. Just can't figure it out.

 
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To clarify, the second mystery bolt up near the intake, I believe it is the one circled in red in the attached diagram. The diagram doesn't clearly show what it goes into though.



side note: wish I new how to easily post pics in line in my post, but don't want to upload the pic to the web first and it looks like inline pics require a URL to the pic... sigh.

 
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Hotlink the URL of any image: Click that icon and paste the URL into the popup.

 
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Yes, but you have to have a URL for the image, which I assume means you have to upload it to some sight like imagebucket or dropbox or something like that. Is there a way to use the hot link for image you have uploaded to this sight or thread?

 
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You don't need to do that. EDIT: I still can't read LOL

On a windows machine...

Hover pointer over an image on a webpage
right click mouse
select "view image info"
a window pops up with the URL of the image highlighted (among many other lines of info not highlighted)
copy URL

I dunno, I've never done it that way

 
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I am just slow maybe. The problem is this is an image that doesn't yet have a URL. It is being posted to this forum, and doesn't live on the ether anywhere else. I suppose the answer is to host the image first on some other site like imagebucket or dropbox. Or perhaps to attach the image here as an attachment, then view the post and right click on the image to get the URL. I will try that.

 
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That seemed to do it. (See post #5)

 
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Alright, now back to the mystery. I studied the diagram a bit more and the bolt seemed to be lining up on the top of the metal mating plate. Sure enough, I was missing the top middle bolt. Don't know how I missed that one. I put it in at 17lbs per spec, didn't go back through and loosen all the others and do it in a criss cross pattern though. I think it will be ok...

So half of the mystery is solved thanks to EZone. Thank you for the great pic.

 
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Still trying to figure out what this bolt is for. If you know what goes in the hole in this picture, kindly reply . By the way, the hole is just to the left of the harmonic balancer.

 
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i have not been in that area for awhile now, the only thing that comes to my mind would be an alternator mounting bracket/bolt, although it appears to be a bit small for that from the pic

 
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Pull the camera back a bit for a wider view, I can't see the forest for the trees.
Still looks like the oil pump right now.

What size is your leftover bolt? Does it thread into the hole?

 
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It's an oil pump bolt hole

 
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Bolt size 6mm x 35mm
wrench size 10mm?

 
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I don't see it in this picture. I could just try putting the bolt in the hole and not fastening anything with it. Would make sense I guess if it is securing the oil pump?

 
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Went in nice an easy with 7.2 ft lbs. Feeling kinda dumb now.

I am sure that was the right place.

OK, so just about to fill her up with coolant, oil and tranny fluid and give it a whirl, but a couple other mysteries to solve.

1) I have one left over part. It is a very small rubber bolt cover about a quarter to a half inch long and hollow, looks like it might fit over a 6mm or smaller bolt ending. Kinda looks like a .22 caliber rubber bullet. I remember taking it off of the alternator, but can't figure out where.

2) Also near the alternator, I have an electrical connector which is hanging behind the driver side cooling fan. It is plugged in, but it is connected to a mounting plate that has a small sharp screw on it. Can't figure out where to screw that in to, so it is currently hanging loose behind the cooling fan which isn't good.

3) There is another electrical plug / connector, currently plugged in, but hanging loose. It is underneath the intake manifold behind the engine. I think it is the knock sensor, connects into the block near the coolant drain bolt. The plug has a little slit where it will connect to a mounting bracket, but not sure where to find the mounting bracket.

4) Last but not least, I connected the exhaust manifold and used a shiny new copper exhaust flange. I noticed when I torqued the spring bolts to the required torque, I can still look at the connection and see a good portion of the copper flange from the passenger side looking down. Wondering if this is normal.

Very close to finishing up the engine head resurfacing, timing belt, cooling system overhaul, etc. Want to give it a start, but thinking I should figure these things out first lest I forget.

 
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Pictures
Pictures
Pictures
Pictures
!!!!!!

Most stuff unplugged will set codes right away, then you can see what they were.

Copper?

 
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Ok, going out to snap some pics. Be right back

 
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Ok, first, the mysterious rubber bullet that goes on the alternator somewhere. Here are a couple pics:






Second, here are the pics of the connector behind the driver side cooling fan:

 
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Ok, now for the connector below in the intake manifold, I believe the knock sensor. You will see the two currently unconnected parts. hoping this doesn't mean I have to take of the intake manifold or something crazy. Here is a pic:



And finally, problem #4. The visible exhaust flange:

 
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Mystery 3 solved (the knock sensor). Saw a mounting bracket behind the passenger side intake support bracket. Removed the support bracket, attached the clip to the mounting bracket and plugged it in.

Guessing the exhaust flange exposure is normal. Also guessing the little plastic bolt cap is not all that important. So really just need to solve the front mounting clip for the electrical connector.

 
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First looks like a vacuum nipple that would plug off a vacuum port. I can't think of why one would be near the alt though.

Second looks like the compressor connector. Secures to the fan shroud.

Third, oil pressure switch.
If the other open connector hanging above it also has a yellow/red wire, those connect together.

4th, that's normal but I've not noticed ours being bare copper color. The joint has to have room to flex with engine movement.

 
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The copper flange was part of a felpro head gasket kit. Don't think the honda ones are the same color.

going to look for the connector on the fan shroud.

 
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Well, an hour later, I was able to get the mounting clip connected to the fan shroud without removing the radiator and disconnecting all the pipes. What a PITA!

Thanks ezone for point me in the right direction.

Giving up on the little .22 caliber rubber nipple. Cant figure out what it is for. I definitely remember removing it from the alternator area, and labeled it as such, but thinking back, it could have been the AC compressor?

Exhaust flange is good I guess. Time to fill it full of fluids and see what happens.

 
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have you survived the "firing it up" experience? (LOL, sorry, your username made this even funnier )

 
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I did indeed survive. Engine is purring and sounds great!

 
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That's what I like to hear!