ENGINE-4.6 & 5.4L: Other Ford Econoline E250

Engine Component View

The concept of modularity allows engine designs to share communizations between concepts and engine hardware. The four modules are the

1. Intake module
2. Cylinder head module (RH)
3. Cylinder head module (LH)
4. Lower engine module

The modular engine concept supports efficiencies during repairs by allowing the removal and installation of these modules. While not all in-vehicle repairs can take advantage of the modular concept, most out-of-vehicle repairs benefit in reduction of time and labor needed to repair the engine.

The basic engine components consist of

1. Single overhead camshafts.
2. Two valves per cylinder.
3. Sequential multiport fuel injection (SFI).
4. Aluminum cylinder heads.
5. Individual ignition coils for each spark plug.
6. Cast iron, 90-degree V-cylinder block.
7. On 4.6L engines, two-piece intake manifold system.
8. Composite-material lower intake manifold with noise insulator.
9. Large-bore throttle body.

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For basic engine mechanical concerns, refer to ENGINE SYSTEM-GENERAL INFORMATION .

For driveability concerns, refer to the INTRODUCTION - CNG, FLEX-FUEL & GASOLINE article.

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1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Disconnect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(ref-210161) .
5. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
6. Position the engine air cleaner (ACL). Remove the four bolts. Loosen the clamp. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
7. Disconnect the MAF sensor electrical connector and remove the ACL.
8. Disconnect the two hoses.
9. Loosen the clamp and remove the air cleaner outlet pipe.
10. Remove the accelerator cable snow shield.
11. Compress and slide the hose clamp and disconnect the upper radiator hose.
12. Remove the bolt retaining the transmission fluid filler tube support bracket.
13. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
14. Disconnect the evaporative emission canister purge valve hose and vacuum hose.
15. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
16. Disconnect the throttle body control linkage. Disconnect the accelerator cable. Disconnect the speed control actuator cable. Disconnect the throttle control return spring.
17. Remove the bolts retaining the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.
18. Disconnect the connector from the throttle position (TP) sensor.
19. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor electrical connector.
20. Disconnect the vacuum hoses from the EGR valve tube.
21. Remove the exhaust manifold to EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
22. Disconnect the EGR vacuum regulator solenoid electrical connector and the vacuum hoses.
23. Disconnect the following hoses: The brake booster vacuum hose. The positive crankcase ventilation (PCV) valve hose. The coolant hose. The IAC valve fresh air hose.
24. Disconnect the IAC valve electrical connector and the EGR valve vacuum connector.
25. Disconnect the coolant hoses and the emissions tube.
26. Remove the four bolts, and the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
27. Disconnect the eight coil-on-plug electrical connectors.
28. Disconnect the eight fuel injector electrical connectors.
29. Remove the eight bolts and the eight ignition coils.
30. Remove the bolts and the generator upper support bracket.
31. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
32. Remove the bolts, thermostat housing and thermostat. Discard the O-ring seal.
33. Remove the nine bolts.
34. Remove the intake manifold assembly. Lift the intake manifold. Disconnect the intake manifold tuning valve electrical connector. Remove the intake manifold and discard the gaskets. Inspect the intake manifold assembly for damage.

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1. Clean all the sealing surfaces.
2. Install the upper intake manifold. Position the new intake manifold gaskets. Position the upper intake manifold. Loosely install nine bolts.
3. Connect the intake manifold tuning valve electrical connector.
4. Install the thermostat. Install the thermostat. Install a new O-ring seal.
5. Install the thermostat housing and loosely install the bolts.
6. Tighten the 11 bolts in two stages in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
7. Connect the fuel pressure sensor electrical connector and the vacuum hose.
8. Install the generator upper support bracket.
9. Install the eight ignition coils and bolts.
10. Connect the eight fuel injector electrical connectors.
11. Connect the eight coil-on-plug electrical connectors.
12. Position a new throttle body adapter gasket and install the throttle body adapter assembly.
13. Connect the coolant hoses and the emissions tube.
14. Connect the IAC valve electrical connector and the EGR valve vacuum connector.
15. Connect the following vacuum hoses: The brake booster vacuum hose. The positive crankcase ventilation (PCV) valve hose. The coolant hose. The IAC fresh air hose.
16. Connect the EGR vacuum regulator solenoid electrical connector and the vacuum hoses.
17. Install the exhaust manifold to EGR valve tube. Hand-tighten the upper and lower fittings. Tighten the fittings to 40 Nm (30 lb-ft).
18. Connect the differential pressure feedback EGR sensor vacuum hoses to the EGR valve tube.
19. Connect the differential pressure feedback EGR sensor electrical connector.
20. Connect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(ref-210161) .
21. Connect the TP sensor electrical connector.
22. Position the accelerator cable bracket and install the bolts.
23. Connect the throttle body control linkage. Connect the accelerator cable. Connect the speed control actuator cable. Connect the throttle control return spring.
24. Install the accelerator cable snow shield.
25. Connect the evaporative emission canister purge valve hoses.
26. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
27. Install the transmission fluid filler tube bracket and bolt.
28. Install the evaporative emission canister purge valve and bracket.
29. Install the upper radiator hose and position the clamp.
30. Install the air cleaner outlet pipe and tighten the clamp.
31. Connect the two hoses to the air cleaner outlet pipe.
32. Connect the MAF sensor and position the ACL.
33. Install the ACL. Install the four bolts. Tighten the clamp.
34. Install the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
35. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
36. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Disconnect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(ref-210161) .
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
5. Position the engine air cleaner (ACL). Remove the four bolts. Loosen the clamp. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the two hoses.
8. Loosen the clamp and remove the air cleaner outlet pipe.
9. Remove the accelerator cable snow shield.
10. Disconnect the throttle body controls. Disconnect the accelerator cable. Disconnect the speed control actuator cable. Remove the throttle return spring.
11. Compress and slide the hose clamp and disconnect the upper radiator hose.
12. Disconnect the coolant hose.
13. Disconnect the coolant hose.
14. Disconnect the throttle position (TP) sensor. Disconnect the TP sensor electrical connector. Detach the harness routing clip.
15. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system. Disconnect the electrical connector. Disconnect the two hoses.
16. Remove the differential pressure feedback EGR system bracket.
17. Remove the bolt and the bracket.
18. Remove the bolts and the generator upper support bracket.
19. Remove the bolt retaining the transmission fluid filler tube support bracket.
20. Remove the bolts and position the accelerator cable bracket and cables aside.
21. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
22. Disconnect and remove the idle air control (IAC) valve fresh air hose.
23. Disconnect the evaporative emission canister purge valve hose and vacuum hose.
24. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
25. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
26. Disconnect the EGR vacuum regulator solenoid connections.
27. Disconnect the EGR valve vacuum hose.
28. Disconnect the IAC valve electrical connector.
29. Disconnect the brake booster and main engine vacuum harness and position aside.
30. Disconnect the differential pressure feedback EGR sensor hoses from the EGR valve.
31. Remove the exhaust manifold-to-EGR valve tube. Disconnect the upper fitting. Disconnect the lower fitting and remove the tube.
32. Remove the four bolts, and the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
33. Disconnect and remove the positive crankcase ventilation hose.
34. Disconnect the eight ignition coil electrical connectors.
35. Disconnect the eight fuel injector electrical connectors.
36. Remove the eight bolts and the eight ignition coils.
37. Remove the bolts, the thermostat housing and the thermostat. Disconnect the O-ring seal.
38. Remove the nine bolts retaining the intake manifold.
39. Remove the intake manifold. Discard the intake manifold gaskets.
40. Inspect the throttle body, the intake manifold, and their sealing surfaces for damage.

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1. Clean and inspect all sealing surfaces.
2. Position the intake manifold gaskets and the intake manifold.
3. Loosely install the nine bolts.
4. Install the thermostat. Install the thermostat. Install a new O-ring seal.
5. Loosely install the thermostat housing and bolts.
6. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
7. Install the eight ignition coils and bolts.
8. Connect the eight fuel injector electrical connectors.
9. Connect the eight ignition coil electrical connectors.
10. Install the PCV hose and valve.
11. Install the new throttle body adapter gasket.
12. Install the throttle body and adapter assembly.
13. Install the exhaust manifold-to-EGR valve tube and tighten the fitting in two stages. Hand-tighten the fittings. Tighten the fittings to 50 Nm (37 lb-ft).
14. Connect the differential pressure EGR sensor hoses to the EGR valve tube.
15. Connect the brake booster and the main engine vacuum harnesses.
16. Connect the IAC electrical connector.
17. Connect the EGR vacuum hose.
18. Connect the EGR vacuum regulator solenoid connections.
19. Connect the fuel pressure sensor vacuum hose and electrical connector.
20. Install the evaporative emission canister purge valve and bracket.
21. Connect the evaporative emission canister purge valve hoses.
22. Connect the IAC fresh air hose.
23. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
24. Connect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(ref-210161) .
25. Install the accelerator cable bracket.
26. Install the transmission fluid filler tube bracket and bolt.
27. Install the generator upper support bracket.
28. Install the accelerator cable routing bracket.
29. Install the differential pressure feedback EGR system bracket.
30. Connect the differential pressure feedback EGR sensor. Connect the electrical connector. Connect the two hoses.
31. Connect the TP sensor. Connect the electrical connector. Attach the harness routing clip.
32. Connect the coolant hose.
33. Connect the coolant hose.
34. Connect the upper radiator hose.
35. Connect the throttle controls. Connect the accelerator cable. Connect the speed control actuator cable. Install the throttle return spring.
36. Install the accelerator cable snow shield.
37. Install the air cleaner outlet pipe and tighten the clamp.
38. Connect the two hoses to the air cleaner outlet pipe.
39. Connect the MAF sensor and position the ACL.
40. Install the ACL. Install the four bolts. Tighten the clamp.
41. Install the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
42. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
43. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Valve Cover LH

MATERIAL

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Remove the crankcase ventilation tube from the valve cover.
5. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor hoses from the EGR valve tube.
6. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
7. Disconnect the differential pressure EGR feedback sensor hose from the EGR valve tube.
8. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
9. Disconnect the LH fuel injector electrical connectors, ignition coil electrical connectors and the wire harness retainers.
10. Disconnect the camshaft position (CMP) sensor.
11. Disconnect the LH radio interference capacitor.
12. Position the engine control wiring harness off of the valve cover.
13. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
2. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
3. Position the valve cover and gasket on the cylinder head. Loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Tighten the bolts in the sequence shown.
6. Position the engine control wiring harness onto the valve cover.
7. Connect the LH radio interference capacitor electrical connector.
8. Connect the CMP electrical connector.
9. Connect the LH ignition coil and fuel injector electrical connectors and the wiring harness retainers.
10. Install the EGR valve tube. Hand-tighten the upper and lower fittings. Tighten to 40 Nm (30 lb-ft).
11. Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.
12. Install the EGR valve tube. Hand-tighten the upper and lower fittings. Tighten to 50 Nm (37 lb-ft).
13. Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.
14. Connect the crankcase ventilation tube to the valve cover.
15. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
16. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
17. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181)

Valve Cover RH - 4.6L

MATERIAL

MATERIAL SPECIFICATIONS

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Disconnect the hose and position it aside, then remove the PCV valve from the valve cover.
5. Remove the clamp and oil filler tube from the valve cover.
6. Remove the fuel charging wiring harness from the valve cover studs and position aside.
7. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
2. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
3. Position the valve cover on the cylinder head, and install the bolts loosely.
4. Tighten the bolts in the sequence shown.
5. Install the PCV valve in the valve cover and connect the hose.
6. Install the fuel charging wiring on the valve cover studs.
7. Install the oil filler tube and clamp on the valve cover.
8. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
9. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
10. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Valve Cover RH - 5.4L

MATERIAL

MATERIAL SPECIFICATIONS

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
3. Remove the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Disconnect the oil fill tube.
5. Remove the crankcase ventilation tube.
6. Disconnect the radio ignition interference capacitor.
7. Disconnect the engine wiring harness connectors.
8. Remove the connectors from the bracket.
9. Remove the ground strap and remove the bracket.
10. Disconnect the A/C compressor connector and the crankshaft position sensor connector.
11. Remove the fuel charging wiring from the valve cover studs.
12. Disconnect the RH fuel injector connectors.
13. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION-4.6L & 5.4LL (2V)»(ref-210145) .
14. Position the fuel charging wiring in the passenger compartment.
15. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
2. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
3. Position the valve cover on the cylinder head and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Position the fuel charging wiring on the engine.
6. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION-4.6L & 5.4L (2V)»(ref-210145) .
7. Connect the RH fuel injector connectors.
8. Position the fuel charging wiring on the valve cover studs.
9. Connect the A/C compressor and the crankshaft position sensor electrical connectors.
10. Install the bracket and ground strap.
11. Install the engine wiring harness connectors on the bracket.
12. Connect the engine wiring harness connectors.
13. Connect the radio ignition interference capacitors.
14. Install the crankcase ventilation tube.
15. Connect the oil fill tube.
16. Install the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
17. Install the air cleaner outlet pipe and the engine air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
18. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Crankshaft Pulley

SPECIAL TOOL(S)

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MATERIAL

MATERIAL SPECIFICATIONS

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1. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
2. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
3. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
4. Remove and discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

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1. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install a new crankshaft pulley bolt. Tighten the bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Lower the vehicle.
5. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
6. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Crankshaft Front Seal

SPECIAL TOOL(S)

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MATERIAL

MATERIAL SPECIFICATIONS

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1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-210135-S32149646182005121300000) .
2. Using the special tool, remove the crankshaft front seal.

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1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal into the engine front cover.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-210135-S32149646182005121300000) .

Engine Front Cover

MATERIAL

MATERIAL SPECIFICATIONS

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove both of the valve covers. For additional information, refer to «VALVE COVER LH»(ref-210135-S30318019232005121300000) , «VALVE COVER RH - 4.6L»(ref-210135-S09649462802005121300000) or «VALVE COVER RH - 5.4L»(ref-210135-S03652619372005121300000) .
3. Remove the radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
4. Remove the water pump. For additional information, refer to «ENGINE COOLING»(ref-210139) .
5. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
6. Remove the top bolts and the lower bolt and position the power steering pump aside.
7. Disconnect the crankshaft position (CKP) sensor electrical connector.
8. Remove the drain plug and drain the engine oil.
9. Remove the oil pan front bolts.
10. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-210135-S04286301882005121300000) .
11. Disconnect the camshaft position (CMP) sensor electrical connector.
12. Remove the bolt and the belt idler pulley.
13. Remove the bolts.
14. Remove the engine front cover from the front cover to cylinder block dowel. Discard the engine front cover gasket. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

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1. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.
3. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
4. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
5. Position the belt idler pulley and install the bolt.
6. Connect the CMP sensor electrical connection.
7. Install a new crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-210135-S04286301882005121300000) .
8. Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
9. Connect the crankshaft position sensor electrical connector.
10. Position the power steering pump and install the bolts.
11. Install the drain plug.
12. Install the valve covers. For additional information, refer to «VALVE COVER LH»(ref-210135-S30318019232005121300000) , «VALVE COVER RH - 4.6L»(ref-210135-S09649462802005121300000) or «VALVE COVER RH - 5.4L»(ref-210135-S03652619372005121300000) .
13. Fill the engine with clean engine oil.
14. Install the water pump. For additional information, refer to «ENGINE COOLING»(ref-210139) .
15. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Timing Drive Components - Windsor Engine (5.4L)

SPECIAL TOOL(S)

Scheme 421

MATERIAL

MATERIAL SPECIFICATIONS

Timing Drive Components - Romeo Engine (4.6L)

SPECIAL TOOL(S)

Scheme 422

MATERIAL

MATERIAL SPECIFICATIONS

Valve Springs

SPECIAL TOOL(S)

Scheme 423

Scheme 424

Scheme 425

Scheme 426

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) .
2. Position the piston at the top of the stroke.
3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal.
4. Use the special tool to compress the valve springs.
5. Remove the valve springs. Remove the valve spring retainer keys. Remove the valve spring retainers. Remove the valve springs.

Scheme 427

Scheme 428

Scheme 429

1. Position the valve spring and the valve spring retainers.
2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
3. Use the special tool to compress the valve spring. Install the valve spring retainer keys.
4. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) .
5. Install the spark plug.

Valve Seals

SPECIAL TOOL(S)

Scheme 430

Scheme 431

1. Remove the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-210135-S33257409272005121300000) .
2. Remove the valve stem seals.

Camshaft Roller Follower

SPECIAL TOOL(S)

Scheme 432

Scheme 433

Scheme 434

Scheme 435

1. Remove the valve cover (6582). For additional information, refer to «VALVE COVER LH»(ref-210135-S30318019232005121300000) , «VALVE COVER RH - 4.6L»(ref-210135-S09649462802005121300000) or «VALVE COVER RH - 5.4L»(ref-210135-S03652619372005121300000) .
2. Position the piston (6108) of the cylinder being repaired at the bottom of the stroke.
3. Install the special tool between the valve spring coils to prevent valve stem seal damage.
4. Use the special tool to compress the valve springs (6513) and remove the camshaft roller followers.

Scheme 436

Scheme 437

1. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers.
2. Remove the special tool.
3. Install the valve covers. For additional information, refer to «VALVE COVER LH»(ref-210135-S30318019232005121300000) , «VALVE COVER RH - 4.6L»(ref-210135-S09649462802005121300000) or «VALVE COVER RH - 5.4L»(ref-210135-S03652619372005121300000) .

Camshaft

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 438

Scheme 439

Scheme 440

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) . CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur.
2. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(ref-210135-S03830668532005121300000) or «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(ref-210135-S32465188892005121300000) .
3. Remove the camshaft sprocket. Remove the bolt. Remove the camshaft sprocket.
4. Remove the bolts, the bearing caps and the camshaft.
5. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
6. Remove the bolts, the bearing caps and the camshaft.
7. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.

Scheme 441

Scheme 442

Scheme 443

Scheme 444

Scheme 445

Scheme 446

1. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Lubricate the camshaft journals with clean engine oil.
3. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
4. Tighten the bolts in the sequence shown.
5. Install the camshaft sprocket. Install the sprocket. Install and tighten the bolt. Tighten in two stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
6. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
7. Tighten the bolts in the sequence shown.
8. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - Romeo Engine (4.6L)»(ref-210135-S03830668532005121300000) or «TIMING DRIVE COMPONENTS - Windsor Engine (5.4L)»(ref-210135-S32465188892005121300000) .
9. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) .

Scheme 447

Scheme 448

Scheme 449

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. On 4x4 vehicles, remove the front wheel opening molding. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
3. Remove the front fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
4. Remove the three-way catalytic converter to exhaust manifold nuts.
5. Remove the eight nuts and the exhaust manifold.
6. Remove and discard the exhaust manifold gasket.
7. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
8. To install, reverse the removal procedure. Tighten the exhaust manifold nuts in the sequence shown.

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor hoses from the EGR valve tube.
4. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
5. Disconnect the differential pressure feedback EGR sensor hoses from the EGR valve tube.
6. Disconnect the upper and lower fittings and remove the EGR valve tube.
7. Remove the front fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
8. Remove the nuts.
9. Remove the nuts and the exhaust manifold.
10. Remove and discard the exhaust manifold gasket.
11. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

Scheme 462

1. Position the exhaust manifold gasket.
2. Position the exhaust manifold and loosely install the nuts.
3. Tighten the nuts in the sequence shown.
4. Install the three-way catalytic converter to exhaust manifold nuts.
5. Install the EGR valve fittings in two stages. Stage 1: Hand-tighten the fittings. Stage 2: Tighten the lower fitting to 50 Nm (37 lb-ft).
6. Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.
7. Install the EGR valve tube in two stages. Stage 1: Connect the upper and lower fittings and hand-tighten. Stage 2: Tighten the fittings to 40 Nm (30 lb-ft).
8. Install the differential feedback EGR sensor hoses to the EGR valve tube.
9. Install the front fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
10. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .

Oil Cooler

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 463

Scheme 464

Scheme 465

Scheme 466

1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
3. Drain the engine oil.
4. Disconnect the coolant hoses.
5. Remove the oil filter.
6. Remove the threaded insert and the oil cooler.
7. Clean and inspect the oil cooler. Plug the coolant connections. Flush the oil passages with parts cleaner. If metal particles are present in the oil cooler, install a new cooler.

Scheme 467

Scheme 468

Scheme 469

1. Position the oil cooler on the oil filter adapter and install the threaded insert.
2. Install a new oil filter.
3. Connect the coolant hoses.
4. Install the oil drain plug.
5. Fill the engine with clean engine oil.
6. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Oil Filter Adapter

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
4. Drain the engine oil.
5. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-210135-S41911236382005121300000) .
6. Disconnect the coolant hoses.
7. Remove the oil filter.
8. Remove the threaded insert and the oil cooler.
9. Disconnect the oil pressure switch electrical connector.
10. Remove the oil pressure switch.
11. Disconnect the lower radiator hose.
12. Remove the nuts, the bolts, the oil filter adapter and the gasket. Discard the gasket.
13. Remove the nut, the bolts, the oil filter adapter and the gasket. Discard the gasket.
14. Clean the gasket surface at the cylinder block.

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

1. Position the oil filter adapter gasket and the oil filter adapter. Install the nuts and bolts.
2. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and bolts.
3. Connect the lower radiator hose.
4. Install the oil pressure switch.
5. Connect the oil pressure switch electrical connector.
6. Position the oil cooler on the oil filter adapter and install the threaded insert.
7. Install a new oil filter.
8. Connect the coolant hoses.
9. Install the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-210135-S41911236382005121300000) .
10. Install the drain plug.
11. Fill the engine with clean engine oil.
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
13. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Oil Level Indicator and Tube

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 488

Scheme 489

1. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
2. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(ref-210135-S19246612812005121300000) .
3. Remove the oil level indicator and the nut retaining the oil level indicator tube and bracket assembly.
4. Remove the bolt.
5. Inspect the oil level indicator tube for damage.

Scheme 490

Scheme 491

1. Lubricate the new O-ring seals with clean engine oil.
2. Insert the oil level indicator tube and install the bolt.
3. Install the nut and insert the oil level indicator.
4. Install the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(ref-210135-S19246612812005121300000) .
5. Install the ACL outlet pipe and the ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .

Oil Pan

SPECIAL TOOL(S)

Scheme 492

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .
2. Remove the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-210139) .
3. Remove the retainers and the shield.
4. Remove the nut and position the transmission fluid filler tube aside.
5. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
6. Disconnect the hose from the heater outlet tube.
7. Remove the heater outlet tube studs.
8. Remove the heater outlet tube.
9. Remove the two transmission-to-engine bolts.
10. Assemble the special tools.
11. Install the special tools.
12. Install the special tool and support the engine.
13. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
14. Drain the engine oil, and remove the oil filter.
15. Remove the four engine mount nuts.
16. Remove the flexplate inspection plate.
17. Lower the vehicle.
18. Using the Heavy Duty Engine Support, raise the engine 10-1/4 inches from the crankshaft pulley to the lower edge of the No. 1 crossmember.
19. Raise the vehicle.
20. Remove the bolts and partially lower the oil pan.
21. Remove the bolts retaining the oil pump screen cover and pickup tube and let the bolts drop into the oil pan.
22. Remove the oil pan at the rear of the engine.
23. Clean the oil pan thoroughly and inspect the oil pan gasket.
24. Clean the mating surfaces for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

Scheme 515

1. Install the oil pump screen and pickup tube.
2. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
3. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
4. Tighten the bolts in three stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Install a new oil filter.
6. Lower the vehicle.
7. Lower the engine and remove the special tools.
8. Raise the vehicle.
9. Install the four engine mount nuts.
10. Install the flexplate inspection plate.
11. Lower the vehicle.
12. Install the transmission-to-engine bolts.
13. Insert the heater outlet tube over the new seals.
14. Install the heater outlet tube studs.
15. Position the transmission fluid filler tube and install the nut.
16. Install the heater outlet tube studs.
17. Position the transmission fluid filler tube and install the nut.
18. Connect the hose to the heater outlet tube.
19. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
20. Install the retainers and the shield.
21. Install the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-210139) .
22. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .
23. Fill the engine with clean engine oil.
24. Start the engine and check for leaks.

Crankshaft Rear Seal

SPECIAL TOOL(S)

Scheme 516

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 517

Scheme 518

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-210135-S09709327692005121300000) .
2. Use the special tools to remove the crankshaft rear oil slinger.
3. Use the special tools to remove the crankshaft rear oil seal.

Scheme 519

1. Clean and inspect the mating surface.
2. Use the special tools to install the crankshaft rear seal.
3. Using the special tools, install the crankshaft rear oil slinger.
4. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-210135-S09709327692005121300000) .

Crankshaft Rear Seal with Retainer Plate

SPECIAL TOOL(S)

Scheme 520

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 521

Scheme 522

Scheme 523

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-210135-S34324257092005121300000) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-210135-S09709327692005121300000) .
3. Use the special tools to remove the crankshaft rear oil seal slinger.
4. Use the special tools to remove the crankshaft rear seal.
5. Remove the six bolts and the crankcase rear seal retainer.

Scheme 524

Scheme 525

Scheme 526

1. Clean and inspect the mating surface.
2. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
3. Install the rear oil seal retainer and loosely install the six bolts.
4. Tighten the bolts in the sequence shown.
5. Use the special tools to install the rear seal.
6. Using the special tools, install the crankshaft rear oil slinger.
7. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-210135-S09709327692005121300000) .
8. Install the oil pan. For additional information, refer to «OIL PAN»(ref-210135-S34324257092005121300000) .

Engine Support Insulators

SPECIAL TOOL(S)

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .
2. Remove the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-210139) .
3. Remove the retainers and the shield.
4. Remove the nut and position the transmission fluid filler tube aside.
5. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
6. Disconnect the hose from the heater outlet tube.
7. Remove the heater outlet tube studs.
8. Remove the heater outlet tube.
9. Remove the two transmission-to-engine bolts.
10. Assemble the special tools.
11. Install the special tools.
12. Install the special tool and support the engine.
13. Raise the vehicle on the hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
14. For the RH front engine support insulator, remove the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
15. Remove the nuts.
16. Lower the vehicle.
17. Using the Heavy Duty Engine Support, raise the engine.
18. Raise the vehicle.
19. Remove the bolts and remove the insulators from the vehicle.

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

1. Position the insulators and install the bolts.
2. Lower the vehicle.
3. Using the Heavy Duty Engine Support, lower the engine.
4. Raise the vehicle.
5. Install the nuts.
6. For the RH front engine support insulator, install the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
7. Lower the vehicle.
8. Remove the special tool.
9. Remove and disassemble the special tools.
10. Install the two transmission-to-engine bolts.
11. Insert the heater outlet tube over the new seals.
12. Install the heater outlet tube studs.
13. Position the transmission fluid filler tube and install the nut.
14. Install the heater outlet tube studs.
15. Position the transmission fluid filler tube and install the nut.
16. Connect the hose to the heater outlet tube.
17. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
18. Position the shield and install the retainers.
19. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
20. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .

SPECIAL TOOL(S)

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

Scheme 570

Scheme 571

Scheme 572

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Scheme 592

Scheme 593

1. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. With the vehicle in NEUTRAL, position it on a hoist, For additional information, refer to «JACKING & LIFTING»(ref-210109) .
3. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .
4. Remove the front bumper. For additional information, refer to «BUMPERS»(ref-210212) .
5. Disconnect the lower radiator hose from the radiator. Disconnect the hose hanger. Disconnect the hose.
6. Remove the pushpin retainers and the splash shield.
7. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
8. Disconnect the exhaust system from the LH and RH exhaust manifolds.
9. Drain the engine oil.
10. Disconnect the oil cooler hoses and set aside.
11. Remove the oil filter.
12. Loosen the threaded insert and remove the oil cooler from the oil filter adapter.
13. Remove the starter motor solenoid terminal cover.
14. Disconnect the starter motor electrical connections.
15. Remove the starter motor. Remove the stud bolt. Remove the two bolts. Remove the starter.
16. Remove the flexplate inspection cover.
17. Remove the cylinder block opening cover.
18. Remove the four nuts retaining the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts. Discard the torque converter nuts.
19. Disconnect the shift cables and the mounting bracket. Disconnect the clip. Remove the bolts.
20. Remove the two transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
21. Remove the RH lower transmission-to-engine bolt.
22. Remove the four engine mount nuts.
23. Disconnect the power steering reservoir hose and the power steering pressure tube at the power steering pump. Allow the fluid to drain into a drain pan.
24. Remove the nut and position the transmission fluid cooler support bracket aside.
25. Remove the valance panel. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
26. Disconnect the upper radiator hose and the degas hose from the radiator.
27. Remove the fan blade assembly and fan clutch. Use the special tool to hold the coolant pump pulley. Using the special tool, remove the fan blade and the fan clutch.
28. Disconnect the degas hose retainer from the fan shroud.
29. Remove the fan shroud, the fan, and the fan clutch. Remove the bolts. Lift the fan shroud, the fan, and the fan clutch from the vehicle.
30. Remove the bolts and the radiator support brackets.
31. Remove the radiator from the vehicle.
32. Disconnect the A/C pressure cutoff switch electrical connector.
33. Disconnect the compressor suction tube.
34. Disconnect the condenser core refrigerant tubes. Disconnect the compressor discharge tube. Disconnect the condenser-to-evaporator tube.
35. Remove the A/C condenser core. Remove the bolts. Remove the A/C condenser brackets. Remove the A/C condenser core.
36. Set the hood latch aside. Remove the hood latch bolts. Disengage the cable routing clip.
37. Remove the bolts and set the power steering reservoir aside.
38. Remove the nuts and the battery feed cable at the power distribution box.
39. Set aside the battery feed wiring harness to the power distribution box. Disengage the routing clips.
40. Remove the eight bolts and the upper radiator support.
41. Remove the pin-type retainers and the RH and LH air deflectors.
42. Set aside the LH side of the headlamp dash panel junction wiring harness. Remove the screw. Disengage the routing clips.
43. Set aside the RH side of the headlamp dash panel junction wiring harness. Disconnect the electrical connector. Remove the screw. Disengage the routing clips.
44. Remove the 12 bolts and the lower radiator support.
45. Disconnect the lower radiator hose from the oil filter adapter water inlet and set aside.
46. Rotate the tensioner clockwise to release belt tension and remove the drive belt.
47. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
48. Remove the bolts and the generator.
49. Disconnect the electrical connectors, remove the nut, and remove the ground strap and mounting bracket.
50. Remove the engine oil filler tube support strap bolt.
51. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube. Remove the fluid level indicator. Disconnect the rear heater hose hanger.
52. Disconnect the evaporative emission canister purge valve electrical connector.
53. Remove the nut and the transmission fluid filler tube, and allow the fluid to drain into a suitable container.
54. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
55. Disconnect the hose from the heater outlet tube.
56. Remove the heater outlet tube studs.
57. Remove the heater outlet tube.
58. Release the transmission wiring harness connector retainer from the bracket. Disconnect the transmission wiring harness and the LH and RH heated oxygen sensor (HO2S) electrical connectors.
59. Remove the four upper transmission-to-engine bolts and the fuel line, and the LH HO2S brackets.
60. Install the special tool as shown.
61. Support the transmission with a jack.
62. Remove the engine from the vehicle.

Cylinder Heads - 4.6L

SPECIAL TOOL(S)

Scheme 594

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

Scheme 624

Scheme 625

Scheme 626

1. Remove the engine. For additional information, refer to «ENGINE»(ref-210135-S01320247142005121300000) .
2. Remove the bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
5. Install the special tool.
6. Install the special tool.
7. Mount the engine on a suitable work stand.
8. Remove the special tool.
9. Remove the special tool.
10. Remove the RH engine mount.
11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Disconnect the RH radio frequency interference capacitor electrical connector.
15. Disconnect the knock sensor electrical connector.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Disconnect the oil pressure switch electrical connector.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the nuts and the two radio interference capacitors.
20. Remove the crankcase ventilation tube from the LH valve cover.
21. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
22. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
23. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
24. Remove the bolt and the belt idler pulley.
25. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
26. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
27. Use the special tool to remove the crankshaft front seal.
28. Remove the power steering pump.
29. Remove the four oil pan bolts.
30. Remove the fasteners.
31. Remove the engine front cover from the cylinder block.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Remove the eight spark plugs.
34. Install the special tool between the valve spring coils to prevent valve stem seal damage.
35. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
36. Position the crankshaft with the keyway at the 12 o'clock position.
37. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
38. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
39. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
40. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
41. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
42. Remove the bolt and the oil level indicator tube.
43. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
44. Install the special tools on both ends of the cylinder head.
45. Remove the hydraulic lash adjusters.
46. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
49. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Cylinder Heads - 5.4L

SPECIAL TOOL(S)

Scheme 627

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

Scheme 640

Scheme 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

1. Remove the engine. For additional information, refer to «ENGINE»(ref-210135-S01320247142005121300000) .
2. Remove the bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
5. Install the special tool.
6. Install the special tool.
7. Mount the engine on a suitable work stand.
8. Remove the special tool.
9. Remove the special tool.
10. Remove the RH engine mount.
11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Disconnect the RH radio frequency interference capacitor electrical connector.
15. Disconnect the knock sensor electrical connector.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Disconnect the oil pressure switch electrical connector.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the nuts and the two radio interference capacitors.
20. Remove the crankcase ventilation tube from the LH valve cover.
21. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
22. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the bolt and the belt idler pulley.
24. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
25. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
26. Use the special tool to remove the crankshaft front seal.
27. Remove the power steering pump.
28. Remove the bolts.
29. Remove the fasteners.
30. Remove the engine front cover from the cylinder block.
31. Remove the crankshaft sensor ring from the crankshaft.
32. Remove the eight spark plugs.
33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
34. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
35. Position the crankshaft with the keyway at the 12 o'clock position.
36. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
37. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
38. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
39. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
40. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
41. Remove the bolt and the oil level indicator tube.
42. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
43. Install the special tools on both ends of the cylinder head.
44. Remove the hydraulic lash adjusters.
45. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
46. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
48. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).

Engine - 4.6L

SPECIAL TOOL(S)

Scheme 658

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

1. Remove the engine. For additional information, refer to «ENGINE - 4.6L»(ref-210135-S25959258862005121300000) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the RH and LH engine mounts.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the knock sensor (KS) electrical connector.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
18. Disconnect the oil pressure switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
22. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
24. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
25. Remove the bolt and the belt idler pulley.
26. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
27. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
28. Use the special tool to remove the crankshaft front seal.
29. Remove the power steering pump.
30. Remove the four oil pan bolts.
31. Remove the fasteners.
32. Remove the engine front cover from the cylinder block.
33. Remove the crankshaft sensor ring from the crankshaft.
34. Remove the eight spark plugs.
35. Install the special tool between the valve spring coils to prevent valve stem seal damage.
36. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
37. Position the crankshaft with the keyway at the 12 o'clock position.
38. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
39. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
40. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
41. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
42. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
43. Remove the bolt and the oil level indicator tube.
44. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
45. Install the special tools on both ends of the cylinder head.
46. Remove the hydraulic lash adjusters.
47. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
49. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
50. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
51. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
52. Clean the oil filter adapter gasket surface at the cylinder block.
53. Remove the bolts.
54. Remove the coolant pump from the cylinder block.
55. Remove the bolts and the A/C compressor.
56. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
57. Remove the bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
58. Remove the bolts and the oil pump screen and pickup tube.
59. Remove the oil pump screen and pickup tube spacer.
60. Remove the oil pump. Remove the bolts. Remove the oil pump.
61. Remove the bolts and the connecting rod cap. Discard the bolts.
62. Use the special tool to push the piston through the top of the cylinder block.
63. Remove the crankshaft bearing cap fasteners. Remove and discard the cross-mounted main cap bolts. Loosen the jack screws. Remove and discard the main cap bolts.
64. Remove the five main bearing caps and the lower crankshaft main bearings.
65. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Engine - 5.4L

SPECIAL TOOL(S)

Scheme 703

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

1. Remove the engine. For additional information, refer to «ENGINE - 5.4L»(ref-210135-S06895140412005121300000) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the RH and LH engine mounts.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the knock sensor electrical connector.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
18. Disconnect the oil pressure switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
22. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
24. Remove the bolt and the belt idler pulley.
25. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
26. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
27. Use the special tool to remove the crankshaft front seal.
28. Remove the power steering pump.
29. Remove the four oil pan bolts.
30. Remove the fasteners.
31. Remove the engine front cover from the cylinder block.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Remove the eight spark plugs.
34. Install the special tool between the valve spring coils to prevent valve stem seal damage.
35. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
36. Position the crankshaft with the keyway at the 12 o'clock position.
37. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
38. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
39. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
40. Remove the nuts, the RH exhaust manifold and gasket. Discard the gasket.
41. Remove the nuts, the LH exhaust manifold and gasket. Discard the gasket.
42. Remove the bolt and the oil level indicator tube.
43. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
44. Install the special tools on both ends of the cylinder head.
45. Remove the hydraulic lash adjusters.
46. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
49. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
50. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
51. Clean the oil filter adapter gasket surface at the cylinder block.
52. Remove the bolts.
53. Remove the coolant pump from the cylinder block.
54. Remove the bolts and the A/C compressor.
55. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent following the manufacturer's instructions.
56. Remove the bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
57. Remove the bolts and the oil pump screen and pickup tube.
58. Remove the oil pump screen and pickup tube spacer.
59. Remove the oil pump. Remove the bolts. Remove the oil pump.
60. Remove the bolts and the connecting rod cap. Discard the bolts.
61. Use the special tool to push the piston through the top of the cylinder block.
62. Remove the fasteners. Remove and discard the cross-mounted main cap bolts. Remove the dowels. Remove and discard the main bearing cap bolts.
63. Remove the five main bearing caps and the lower crankshaft main bearings.
64. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Cylinder Head

SPECIAL TOOL(S)

Scheme 745

MATERIAL

MATERIAL SPECIFICATIONS

SPECIAL TOOL(S)

Scheme 746

Scheme 747

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2". Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the dowel pins so the flat sides face the crankshaft.
12. Install the vertical main bearing cap fasteners and tighten in the sequence shown. Tighten to 40 Nm (30 lb-ft). Tighten an additional 90 degrees.
13. Install the side bolts and tighten them in the sequence shown. Tighten to 30 Nm (22 lb-ft) Tighten an additional 90 degrees.
14. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
15. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
16. Position the lower bearing and connecting rod, and install the new bolts loosely.
17. Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
19. Install the head gasket over the dowel pins.
20. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
21. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
22. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
23. Remove the special tools both ends of the cylinder head.
24. Install the hydraulic lash adjusters in their original locations.
25. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
26. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
28. Compress the tensioner plunger, using a vise.
29. Install a retaining clip on the tensioner to hold the plunger in during installation.
30. Remove the tensioner from the vise.
31. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
32. Install the timing chain guides.
33. Pre-position the camshaft. Rotate the LH camshaft until mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
34. Position the crankshaft so the number one cylinder is at TDC with the special tool.
35. Remove the Crankshaft Holding Tool.
36. Install the crankshaft sprocket, making sure the flange faces forward.
37. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
38. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
39. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
40. Remove the retaining clip from the LH timing chain tensioner.
41. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
42. Install the RH timing chain on the camshaft sprocket, Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
44. Remove the retaining clip from the RH timing chain tensioner.
45. As a post-check, verify correct alignment of all timing marks.
46. Install the special tool between the valve spring coils to prevent valve stem seal damage.
47. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
48. Install the eight spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
49. Install the crankshaft sensor ring on the crankshaft.
50. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
51. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
52. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
53. Position the belt idler pulley and install the bolt.
54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
55. Use the special tools to install the crankshaft front seal into the engine front cover.
56. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
57. Use the special tool to install the crankshaft pulley.
58. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
59. Position the power steering pump and install the bolts.
60. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
61. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
62. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
63. Tighten the bolts in the sequence shown.
64. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
65. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
66. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
67. Tighten the bolts in the sequence shown.
68. Install the crankcase ventilation tube on the LH valve cover.
69. Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
71. Connect the CKP sensor electrical connector.
72. Connect the oil pressure switch electrical connector.
73. Connect the KS electrical connector.
74. Connect the RH radio frequency interference capacitor electrical connector.
75. Connect the CMP sensor electrical connector.
76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
77. Install the cylinder block drain plugs.
78. Position a new gasket and the oil filter adapter. Install the bolts and nut.
79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
80. If equipped, install the A/C compressor end the bolts.
81. Install the coolant pump. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the bolts.
82. Position the coolant pump pulley on the coolant pump and install the bolts.
83. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
84. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
86. Tighten the bolts in the sequence shown.
87. Install the oil drain plug before installing the oil pan.
88. Install the oil pump screen and pickup tube spacer.
89. Position the oil pump screen and pickup tube and install the bolts.
90. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
91. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
93. Install the oil pan gasket and the oil pan and loosely install the bolts.
94. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
95. Install the special tool.
96. Install the special tool.
97. Install the special tool and remove the engine from the work stand.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
100. Install the oil level indicator tube nut and insert the oil level indicator.
101. Using the special tools, install a new crankshaft rear seal.
102. Using the special tools, install the crankshaft rear oil slinger.
103. Install the flexplate and bolts. Tighten the bolts in the sequence shown.

SPECIAL TOOL(S)

Scheme 809

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

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Scheme 820

Scheme 821

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Scheme 841

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Scheme 849

Scheme 850

Scheme 851

Scheme 852

1. Position the engine in the vehicle.
2. Remove the floor crane and the jack supporting the transmission.
3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
4. Position the shifter cable support bracket and install the two transmission-to-engine bolts.
5. Install the RH lower transmission-to-engine bolt.
6. Install the mounting bracket and connect the shift cable. Install the bolts. Connect the clip.
7. Install four new nuts to retain the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts.
8. Install the cylinder block opening cover.
9. Install the flexplate inspection cover.
10. Install the four engine mount nuts.
11. Install the starter motor. Position the starter. Install the two bolts. Install the stud bolt.
12. Connect the starter motor electrical connections.
13. Install the starter motor solenoid terminal cover.
14. Mount the exhaust system to the LH and RH exhaust manifolds.
15. Position the oil cooler on the oil filter adapter and install the threaded insert.
16. Install a new oil filter.
17. Connect the oil cooler hoses.
18. Position the transmission fluid cooler tube support bracket and install the nut.
19. Position the fluid cooler tube support bracket and install the nut.
20. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
21. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
22. Install and tighten the oil drain plug.
23. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the four upper transmission-to-engine bolts.
24. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
25. Insert the heater outlet tube over the new seals.
26. Install the heater outlet tube studs.
27. Install the transmission fluid filler tube.
28. Install the heater outlet tube studs.
29. Install the transmission fluid filler tube.
30. Connect the hose to the heater outlet tube.
31. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
32. Connect the evaporative emission canister purge valve electrical connector.
33. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator. Connect the rear heater hose hanger. Install the fluid level indicator.
34. Install the engine oil filler tube support strap bolt.
35. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors.
36. Position the generator and install the bolts.
37. Connect the generator electrical connections. Install the B+ terminal and disconnect the terminal. Connect the S electrical connector. Connect the ASI electrical connector.
38. Rotate the tensioner clockwise and install the drive belt. Refer to the decal on the upper radiator air deflector for belt routing.
39. Connect the lower radiator hose to the oil filter adapter coolant inlet.
40. Position the lower radiator support and install the twelve bolts.
41. Install the RH side of the headlamp dash panel junction wiring harness. Connect the electrical connector. Install the screw. Insert the routing clips.
42. Install the LH side of the headlamp dash panel junction wiring harness. Install the screw. Insert the routing clips.
43. Position the RH and LH air deflectors and install the pin-type retainers.
44. Position the upper radiator support and install the eight bolts.
45. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
46. Install the battery feed cable to the power distribution box.
47. Install the power steering reservoir.
48. Install the hood latch. Install the hood latch. Insert the cable routing clip.
49. Install the A/C condenser core. Position the A/C condenser core in the vehicle. Position the A/C condenser brackets. Install the bolts.
50. Connect the condenser core refrigerant tubes. Connect the condenser to evaporator tube. Connect the compressor discharge tube.
51. Connect the compressor suction tube.
52. Connect the A/C pressure setoff switch electrical connector.
53. Position the radiator in the vehicle.
54. Position the radiator support brackets and install the bolts.
55. Position the fan shroud and the fan and fan clutch in the vehicle, and install the bolts.
56. Insert the degas hose retainer in the fan shroud.
57. Install the fan blade assembly and fan clutch. Install the fan blade and the fan clutch. Use the special tool to hold the coolant pump pulley. Using the special tool, tighten the fan clutch nut.
58. Connect the upper radiator hose and the degas hose to the radiator.
59. Install the valance panel. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
60. Connect the transmission cooler tubes.
61. Position the splash shield and install the pushpin retainers.
62. Connect the lower radiator hose to the radiator. Connect the hose. Connect the hose hanger.
63. Install the front bumper. For additional information, refer to «BUMPERS»(ref-210212) .
64. Fill the engine with clean engine oil.
65. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(ref-210135-S29917744972005121300000) or «INTAKE MANIFOLD - 5.4L»(ref-210135-S06967514782005121300000) .
66. Fill all fluids to the correct levels. Fill the transmission with clean transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION-4R100»(ref-210155) or «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-210156) . Fill the power steering system with clean fluid. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-210123) .
67. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
68. Evacuate and recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

SPECIAL TOOL(S)

Scheme 853

Material

MATERIAL SPECIFICATIONS

Scheme 854

Scheme 855

Scheme 856

Scheme 857

Scheme 858

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Scheme 860

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Scheme 888

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Scheme 896

Scheme 897

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
4. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
5. Remove the special tools from both ends of the cylinder head.
6. Install the hydraulic lash adjusters in their original locations.
7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
8. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark one like on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
15. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
16. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
17. Remove the Crankshaft Holding Tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
20. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. Install the RH timing chain on the camshaft sprocket. Align the copper (marked) link with the timing marks on the sprocket.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
30. Install the eight spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
31. Install the crankshaft sensor ring on the crankshaft.
32. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
33. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
34. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
35. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
36. Position the belt idler pulley and install the bolt.
37. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
38. Use the special tools to install the crankshaft front seal into the engine front cover.
39. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
40. Use the special tool to install the crankshaft pulley.
41. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
42. Position the coolant pump pulley on the coolant pump and install the bolts.
43. Position the power steering pump and install the bolts.
44. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
45. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
47. Tighten the bolts in the sequence shown.
48. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
50. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence shown.
52. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
53. Install the crankcase ventilation tube on the LH valve cover.
54. Install the radio frequency interference capacitors.
55. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
56. Connect the CKP sensor electrical connector.
57. Connect the oil pressure switch electrical connector.
58. Connect the KS electrical connector.
59. Connect the RH radio frequency interference capacitor electrical connector.
60. Connect the CMP sensor electrical connector.
61. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
62. Install the cylinder block drain plugs.
63. Install the RH engine mount. Tighten the bolts to 63 Nm (46 lb-ft).
64. Install the special tool.
65. Install the special tool.
66. Install the special tool and remove the engine from the work stand.
67. Lower the engine onto wooden blocks.
68. Install the special tool and raise the engine.
69. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.
70. Install the engine. For additional information, refer to «ENGINE»(ref-210135-S01320247142005121300000) .

SPECIAL TOOL(S)

Scheme 898

MATERIAL

MATERIAL SPECIFICATIONS

Scheme 899

Scheme 900

Scheme 901

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Scheme 904

Scheme 905

Scheme 906

Scheme 907

Scheme 908

Scheme 909

Scheme 910

Scheme 911

Scheme 912

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Scheme 940

Scheme 941

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
4. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
5. Remove the special tools from both ends of the cylinder head.
6. Install the hydraulic lash adjusters in their original locations.
7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
8. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides.
15. Pre-position the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
16. Position the crankshaft so the number one cylinder is at TDC with the special tool.
17. Remove the Crankshaft Holding Tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
20. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
24. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post-check, verify correct alignment of all timing marks.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
30. Install the eight spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
31. Install the crankshaft sensor ring on the crankshaft.
32. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
33. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
34. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
35. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
36. Position the belt idler pulley and install the bolt.
37. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
38. Use the special tools to install the crankshaft front seal into the engine front cover.
39. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
40. Use the special tool to install the crankshaft pulley.
41. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
42. Position the coolant pump pulley on the coolant pump and install the bolts.
43. Position the power steering pump and install the bolts.
44. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
45. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
47. Tighten the bolts in the sequence shown.
48. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
50. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence shown.
52. Install the crankcase ventilation tube on the LH valve cover.
53. Install the radio frequency interference capacitors.
54. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
55. Connect the CKP sensor electrical connector.
56. Connect the oil pressure switch electrical connector.
57. Connect the KS electrical connector.
58. Connect the RH radio frequency interference capacitor electrical connector.
59. Connect the CMP sensor electrical connector.
60. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
61. Install the cylinder block drain plugs.
62. Install the RH engine mount. Tighten the bolts to 63 Nm (46 lb-ft).
63. Install the special tool.
64. Install the special tool.
65. Install the special tool and remove the engine from the work stand.
66. Lower the engine onto wooden blocks.
67. Install the special tool and raise the engine.
68. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
69. Install the engine. For additional information, refer to «ENGINE»(ref-210135-S01320247142005121300000) .