ENGINE-6.8L: Other Ford Econoline E250

Engine Component View

The concept of modularity allows engine designs to share concepts and hardware. The following illustration represents the basic cross-sectional view of a modular V10 engine. The four modules are

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

Due to the modular design, most out-of-vehicle repairs benefit in reduction of time and labor needed to repair the engine.

Bi-fuel vehicles differ from gasoline vehicles through the addition of hardened valves and valve seats.

The basic engine components consist of

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

Scheme 1090

Scheme 1091

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

Scheme 1096

Scheme 1097

Refer to ENGINE SYSTEM-GENERAL INFORMATION for basic mechanical concerns or refer to the INTRODUCTION - CNG, FLEX-FUEL & GASOLINE article for driveability concerns.

Intake Manifold

MATERIAL

MATERIAL SPECIFICATION

Valve Cover - LH

MATERIAL

MATERIAL SPECIFICATION

Scheme 1098

Scheme 1099

Scheme 1100

Scheme 1101

Scheme 1102

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
4. Remove the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
5. Remove the nuts and position the LH fuel charge wiring harness aside.
6. Disconnect the fuel injector electrical connectors.
7. Disconnect the ten ignition coil electrical connectors.
8. Lift the fuel charging wiring off the valve cover studs.
9. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Inspect the valve cover gasket and clean the mating surface of the cylinder head.

Scheme 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

Scheme 1109

1. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
2. Position the valve cover and the valve cover gasket on the cylinder head and loosely install the bolts.
3. Tighten the bolts in the sequence shown.
4. Position the fuel charging wiring onto the valve cover studs.
5. Position the LH fuel charge wiring harness and install the nuts.
6. Disconnect the fuel injector electrical connectors.
7. Disconnect the ten ignition coil electrical connectors.
8. Remove the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
9. Install the engine air cleaner and engine air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
10. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
11. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Valve Cover - RH

MATERIAL

MATERIAL SPECIFICATION

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
4. Disconnect the oil fill tube from the RH valve cover.
5. Remove the bolt and the oil fill tube.
6. Disconnect the positive crankcase ventilation (PCV) electrical connector and tube.
7. Disconnect the wiring harness retainer from the RH valve cover stud.
8. Remove the nuts and position the RH fuel charge wiring harness aside.
9. 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. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

1. 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 the valve cover gasket on the cylinder head and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Position the RH fuel charge wiring harness and install the nuts.
6. Connect the wiring harness retainer to the RH valve cover stud.
7. Connect the PCV tube and electrical connector.
8. Connect the oil fill tube to the RH valve cover.
9. Install the oil fill tube support bracket bolt.
10. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
11. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
12. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Crankshaft Pulley

SPECIAL TOOL(S)

Scheme 1122

MATERIAL

MATERIAL SPECIFICATION

Scheme 1123

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
3. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
4. Remove the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

Scheme 1124

Scheme 1125

1. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
2. Use the special tool to install the crankshaft pulley.
3. Tighten the 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.
4. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
5. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Crankshaft Front Seal

SPECIAL TOOL(S)

Scheme 1126

MATERIAL

MATERIAL SPECIFICATION

Scheme 1127

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-210138-S12676114582005121300000) .
2. Using the special tool, remove the crankshaft front seal.

Scheme 1128

Scheme 1129

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-210138-S12676114582005121300000) .

Engine Front Cover

MATERIAL

MATERIAL SPECIFICATION

Scheme 1130

Scheme 1131

Scheme 1132

Scheme 1133

Scheme 1134

Scheme 1135

1. With the vehicle in NEUTRAL, position it 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. Remove both of the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-210138-S02573812872005121300000) and «VALVE COVER - RH»(ref-210138-S33170752452005121300000) .
4. Remove the radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
5. Remove the water pump. For additional information, refer to «ENGINE COOLING»(ref-210139) .
6. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-210138-S00285533482005121300000) .
7. Remove the top bolts and the lower bolt and position the power steering pump aside.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove the drain plug and drain the engine oil.
10. Remove the four front oil pan bolts.
11. Disconnect the camshaft position (CMP) sensor electrical connector.
12. Remove the bolt and the accessory drive belt idler pulley.
13. Remove the bolts.
14. Remove the engine front cover from the front cover-to-cylinder block dowel. Remove 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.

Scheme 1136

Scheme 1137

Scheme 1138

Scheme 1139

Scheme 1140

Scheme 1141

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 the engine front cover gasket on the engine front cover-to-cylinder block dowel and loosely install the bolts.
3. Tighten the engine front cover fasteners in sequence in two stages. Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
4. Position the accessory drive belt idler pulley and install the bolt.
5. Connect the CMP electrical connector.
6. Loosely install the bolts, then tighten the bolts in the two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
7. Connect the CKP sensor electrical connector.
8. Position the power steering pump and install the bolts.
9. Install the oil drain plug.
10. Install a new crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-210138-S00285533482005121300000) .
11. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-210138-S02573812872005121300000) and «VALVE COVER - RH»(ref-210138-S33170752452005121300000) .
12. Install the water pump. For additional information, refer to «ENGINE COOLING»(ref-210139) .
13. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
14. Fill the engine with clean engine oil.
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Timing Drive Components

SPECIAL TOOL(S)

Scheme 1142

MATERIAL

MATERIAL SPECIFICATION

Camshaft

SPECIAL TOOL(S)

Scheme 1143

MATERIAL

MATERIAL SPECIFICATION

Oil Cooler

MATERIAL

MATERIAL SPECIFICATION

Scheme 1144

Scheme 1145

Scheme 1146

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
2. Drain the engine oil.
3. Disconnect the coolant hoses.
4. Remove the oil filter.
5. Remove the threaded insert and the oil cooler.
6. To install, reverse the removal procedure. Fill the engine with clean engine oil before filling the cooling system.

Oil Level Indicator and Tube

MATERIAL

MATERIAL SPECIFICATION

Scheme 1147

Scheme 1148

Scheme 1149

Scheme 1150

1. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
2. Remove the oil level indicator and the nut retaining the oil level indicator tube and bracket assembly.
3. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(ref-210138-S35047724792005121300000) .
4. Remove the bolt and the oil level indicator tube.
5. Inspect the oil level indicator tube for damage.
6. To install, reverse the removal procedure. Install new O-ring seals and lubricate them with clean engine oil.

Oil Pan

SPECIAL TOOL(S)

Scheme 1151

MATERIAL

MATERIAL SPECIFICATION

Scheme 1152

Scheme 1153

Scheme 1154

Scheme 1155

Scheme 1156

Scheme 1157

Scheme 1158

Scheme 1159

Scheme 1160

Scheme 1161

Scheme 1162

Scheme 1163

Scheme 1164

Scheme 1165

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-210138-S04698938422005121300000) .
3. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
4. Remove the retainers and the shield.
5. Remove the nut attaching the transmission oil level tube.
6. Disconnect the wiring harness retainer.
7. Remove the stud bolts and position the heater outlet tube aside.
8. Remove the two transmission-to-engine bolts.
9. Disconnect the oil fill tube from the RH valve cover.
10. Removal the bolt and the oil fill tube.
11. Assemble the special tools.
12. Install the special tools.
13. Install the special tool and support the engine.
14. Drain the engine oil and remove the oil filter.
15. Remove the RH and LH nuts retaining the front engine support insulators to the front engine support bracket.
16. Remove the flywheel inspection plate.
17. Using the special tool, raise the engine.
18. Remove the bolts and partially lower the oil pan.
19. Remove the bolts retaining the oil pump screen cover and pickup tube and allow it to drop into the oil pan. Also remove the tube and spacer and allow it to drop into the oil pan. Remove the oil pan.
20. Clean the mating surfaces for the oil pan and the engine with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Scheme 1166

Scheme 1167

Scheme 1168

Scheme 1169

Scheme 1170

Scheme 1171

Scheme 1172

Scheme 1173

Scheme 1174

1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
2. Install the oil pump screen cover and pickup tube. Install and tighten the spacer. Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer. Install and tighten the bolts.
3. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
5. Tighten the bolts 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.
6. Lower the engine and remove the special tools.
7. Install the flywheel inspection plate.
8. Tighten the engine support insulators.
9. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
10. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten the studs to 40 Nm (30 lb-ft).
11. Remove the nut attaching the transmission oil level tube.
12. Connect the wiring harness retainer.
13. Connect the oil fill tube to the RH valve cover.
14. Install the oil fill tube support bracket bolt.
15. Install the transmission-to-engine bolts.
16. Install the shield and the retainers.
17. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-210138-S04698938422005121300000) .
18. Fill the engine with clean engine oil.
19. Install the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
20. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Oil Filter Adapter

MATERIAL

MATERIAL SPECIFICATION

Scheme 1175

Scheme 1176

Scheme 1177

Scheme 1178

Scheme 1179

Scheme 1180

Scheme 1181

Scheme 1182

1. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-210138-S12848231282005121300000) .
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. Disconnect the coolant hoses.
6. Remove the oil filter.
7. Remove the threaded insert and the oil cooler.
8. Disconnect the oil pressure switch electrical connector.
9. Remove the oil pressure switch.
10. Disconnect the lower radiator hose.
11. Remove the nut, the bolts, the oil filter adapter and the gasket. Discard the gasket.
12. To install, reverse the removal procedure. Install a new oil filter adapter gasket. Fill the engine with clean engine oil before filling the cooling system.

Scheme 1183

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-210138-S02948365502005121300000) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-210138-S39482149682005121300000) .
3. Remove the bolts and the oil pump.

Scheme 1184

1. Clean and inspect the mating surfaces.
2. Position the oil pump and loosely install the bolts. Tighten the bolts in the sequence shown.
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-210138-S39482149682005121300000) .
4. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-210138-S02948365502005121300000) .

Scheme 1185

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75»(ref-210156) .
2. Remove the bolts and the flexplate.

Scheme 1186

1. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence shown.
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75»(ref-210156) .

Crankshaft Rear Seal

SPECIAL TOOL(S)

Scheme 1187

MATERIAL

MATERIAL SPECIFICATION

Scheme 1188

Scheme 1189

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-210138-S17013576192005121300000) .
2. Use the special tools to remove the crankshaft rear oil slinger.
3. Use the special tools to remove the crankshaft rear seal.

Scheme 1190

1. Using the special tools, install the crankshaft rear seal.
2. Using the special tools, install the crankshaft rear oil slinger.
3. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-210138-S17013576192005121300000) .

Crankshaft Rear Seal with Retainer Plate

SPECIAL TOOL(S)

Scheme 1191

MATERIAL

MATERIAL SPECIFICATION

Scheme 1192

Scheme 1193

Scheme 1194

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-210138-S17013576192005121300000) .
2. Using the special tools, remove the crankshaft rear oil slinger.
3. Using the special tools, remove the crankshaft rear seal.
4. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-210138-S39482149682005121300000) .
5. Remove the bolts and the crankshaft rear seal retainer plate.

Scheme 1195

Scheme 1196

Scheme 1197

1. Clean and inspect the mating surface.
2. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.
3. Install the crankshaft rear seal retainer plate 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 oil pan. For additional information, refer to «OIL PAN»(ref-210138-S39482149682005121300000) .
8. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-210138-S17013576192005121300000) .

Engine Support Insulators

SPECIAL TOOL(S)

Scheme 1198

MATERIAL

MATERIAL SPECIFICATION

Scheme 1199

Scheme 1200

Scheme 1201

Scheme 1202

Scheme 1203

Scheme 1204

Scheme 1205

Scheme 1206

Scheme 1207

Scheme 1208

Scheme 1209

Scheme 1210

Scheme 1211

1. With the vehicle in NEUTRAL, position it 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. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
5. Remove the generator. For additional information, refer to «GENERATOR & REGULATOR»(ref-213723) .
6. Remove the cooling fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
7. If the RH engine mount is to be serviced, remove the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
8. Position the hose clamp back and disconnect the coolant hose.
9. Remove the accelerator cable splash shield.
10. Disconnect the accelerator and speed control cables and remove the return spring.
11. Position the accelerator cable bracket aside. Remove the bolts. Position the bracket and cables aside.
12. Disconnect the heated positive crankcase valve (PCV) tube and the vacuum hoses.
13. Disconnect the PCV coolant hoses.
14. Disconnect the vacuum tube.
15. Disconnect the idle air control (IAC) motor electrical connector and remove the bypass hose.
16. Disconnect the throttle position (TP) sensor electrical connector.
17. Remove the throttle body (TB) adapter. Remove the four bolts. Remove the TB adapter. Discard the TB adapter press-in-place gasket.
18. Install the special tool on the engine, using the generator mounting holes.
19. Remove the nuts.
20. Install the special tool and raise the engine.
21. Remove the bolts and remove the engine mounts from the vehicle.

Scheme 1212

Scheme 1213

Scheme 1214

Scheme 1215

Scheme 1216

Scheme 1217

Scheme 1218

Scheme 1219

Scheme 1220

Scheme 1221

Scheme 1222

Scheme 1223

Scheme 1224

1. Position the engine mounts and install the bolts.
2. Using a floor crane, remove the special tool.
3. Lower the engine and align the engine mount studs.
4. Remove the floor crane.
5. Install the nuts.
6. Remove the special tool from the engine.
7. Install the TB adapter. Install a new TB adapter gasket. Position the TB adapter. Install the four bolts and tighten in two stages. Stage 1: Tighten the bolts to 9 Nm (80 lb-in). Stage 2: Tighten an additional 90 degrees.
8. Connect the TP sensor electrical connector.
9. Connect the PCV coolant hoses.
10. Connect the heated PCV tube and the vacuum hoses.
11. Connect the IAC motor electrical connector and install the bypass hose.
12. Connect the vacuum tube.
13. Install the accelerator bracket. Position the bracket. Install the bolts.
14. Connect the accelerator and speed control cables and return spring.
15. Install the accelerator cable splash shield.
16. Connect the coolant hose and position the hose clamp.
17. If the RH engine mount was serviced, install the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
18. Install the generator. For additional information, refer to «GENERATOR & REGULATOR»(ref-213723) .
19. Install the engine cooling fan shroud. For additional information, refer to «ENGINE COOLING»(ref-210139) .
20. Install the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
22. Fill the engine with clean engine oil.
23. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

Cylinder Heads

SPECIAL TOOL(S)

Scheme 1225

MATERIAL

MATERIAL SPECIFICATION

Scheme 1226

Scheme 1227

Scheme 1228

Scheme 1229

Scheme 1230

Scheme 1231

Scheme 1232

Scheme 1233

Scheme 1234

Scheme 1235

Scheme 1236

Scheme 1237

Scheme 1238

Scheme 1239

Scheme 1240

Scheme 1241

Scheme 1242

Scheme 1243

Scheme 1244

Scheme 1245

Scheme 1246

Scheme 1247

Scheme 1248

Scheme 1249

Scheme 1250

Scheme 1251

Scheme 1252

Scheme 1253

Scheme 1254

Scheme 1255

Scheme 1256

Scheme 1257

Scheme 1258

Scheme 1259

1. Remove the engine. For additional information, refer to «ENGINE»(ref-210138-S20481162292005121300000) .
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 into 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 (KS) electrical connector, if equipped.
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 positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
21. Remove the nut attaching the oil level indicator tube to the front of the engine.
22. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
23. Position the oil level indicator tube aside.
24. 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.
25. 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.
26. Remove the bolt and the idler pulley.
27. Remove the water pump pulley. Remove the bolts. Remove the water pump pulley.
28. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
29. Using the special tool, remove the crankshaft front seal.
30. Remove the power steering pump.
31. Remove the four oil pan bolts.
32. Remove the fasteners.
33. Remove the engine front cover from the cylinder block.
34. Remove the crankshaft sensor ring from the crankshaft.
35. Remove the six bolts and remove the balance shaft bearing caps.
36. Remove the balance shaft.
37. Remove the 10 spark plugs.
38. Install the special tool between the valve spring coils to prevent valve stem seal damage.
39. Use the special tool to compress the valve springs and remove the camshaft roller followers.
40. Position the crankshaft with the keyway at the 12 o'clock position.
41. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
42. 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 from the crankshaft sprocket.
43. Remove both timing chain guides. Remove the bolts. Remove the timing chain guides.
44. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
45. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
46. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
47. Install the special tools on both ends of the cylinder head.
48. Remove the hydraulic lash adjusters.
49. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
50. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
51. 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 surface is normal.
52. 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).

SPECIAL TOOL(S)

Scheme 1260

Scheme 1261

Scheme 1262

Scheme 1263

Scheme 1264

Scheme 1265

Scheme 1266

Scheme 1267

Scheme 1268

Scheme 1269

Scheme 1270

Scheme 1271

Scheme 1272

Scheme 1273

Scheme 1274

Scheme 1275

1. Discharge and recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Disconnect the 42-pin and the two 16-pin connectors and remove the nut and the harness mounting bracket.
3. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-210138-S04698938422005121300000) .
4. Remove the radiator RH and LH air deflector, the radiator grille support, the valance panel and the upper and lower radiator supports. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
5. Remove the radiator, fan shroud and engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-210139) .
6. Remove the headlamps and side marker lamps. For additional information, refer to «EXTERIOR LIGHTING»(ref-210191) .
7. Remove the A/C condenser core. For additional information, refer to «AIR CONDITIONING»(ref-210171) .
8. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
9. Disconnect the power steering reservoir hose at the power steering pump and let drain into a drain pan.
10. Disconnect the power steering pressure hose.
11. At the oil cooler water inlet, disconnect and set aside the lower radiator hose.
12. Disconnect the suction hose at the accumulator.
13. Disconnect the transmission harness and the left and right heated exhaust gas oxygen sensor connectors.
14. Remove the upper transmission-to-engine bolts and the fuel tube bracket.
15. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
16. Remove the nuts.
17. Drain the engine oil and remove the oil filter.
18. Disconnect the oil cooler hoses and position aside.
19. Loosen the threaded shaft and remove the oil cooler from the oil filter adapter.
20. Remove the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
21. Remove the bolt from the A/C compressor manifold and position the manifold aside.
22. Remove the bolts and position the shift cable and bracket aside.
23. Remove and discard the six nuts retaining the torque converter to the flexplate.
24. Remove the engine support insulator nuts.
25. Remove the remaining transmission to engine bolts.
26. Lower the vehicle.
27. Install the Modular Engine Lift Bracket.
28. Support the transmission with a jack.
29. Remove the engine from the vehicle.

SPECIAL TOOL(S)

Scheme 1276

MATERIAL

MATERIAL SPECIFICATION

Scheme 1277

Scheme 1278

Scheme 1279

Scheme 1280

Scheme 1281

Scheme 1282

Scheme 1283

Scheme 1284

Scheme 1285

Scheme 1286

Scheme 1287

Scheme 1288

Scheme 1289

Scheme 1290

Scheme 1291

Scheme 1292

Scheme 1293

Scheme 1294

Scheme 1295

Scheme 1296

Scheme 1297

Scheme 1298

Scheme 1299

Scheme 1300

Scheme 1301

Scheme 1302

Scheme 1303

Scheme 1304

Scheme 1305

Scheme 1306

Scheme 1307

Scheme 1308

Scheme 1309

Scheme 1310

Scheme 1311

Scheme 1312

Scheme 1313

Scheme 1314

Scheme 1315

Scheme 1316

Scheme 1317

Scheme 1318

Scheme 1319

Scheme 1320

Scheme 1321

Scheme 1322

Scheme 1323

Scheme 1324

Scheme 1325

Scheme 1326

1. Remove the engine. For additional information, refer to «Engine»(ref-210138-S17287709582005121300000) .
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 special tool.
12. Remove the special tool.
13. Remove the RH and LH engine mounts.
14. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
15. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
16. Disconnect the camshaft position (CMP) sensor electrical connector.
17. Disconnect the RH radio frequency interference capacitor electrical connector.
18. Disconnect the knock sensor electrical connector, if equipped.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
20. Disconnect the oil pressure switch electrical connector.
21. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
22. Remove the nuts and the two radio interference capacitors.
23. Remove the crankcase ventilation tube from the LH valve cover.
24. Remove the nut attaching the oil level indicator tube to the front of the engine.
25. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
26. Position the oil level indicator tube aside.
27. 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.
28. 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.
29. Remove the bolt and the idler pulley.
30. Remove the water pump pulley. Remove the bolts. Remove the water pump pulley.
31. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
32. Use the special tool to remove the crankshaft front oil seal.
33. Remove the power steering pump.
34. Remove the bolts.
35. Remove the fasteners.
36. Remove the engine front cover from the cylinder block.
37. Remove the crankshaft sensor ring from the crankshaft.
38. Remove the six bolts and remove the balance shaft bearing caps.
39. Remove the balance shaft.
40. Remove the 10 spark plugs.
41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
42. Use the special tool to compress the valve springs and remove the camshaft roller followers.
43. Remove the special tool.
44. Position the crankshaft with the keyway at the 12 o'clock position.
45. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
46. 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 from the crankshaft sprocket.
47. Remove both timing chain guides. Remove the bolts. Remove the timing chain guides.
48. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
49. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
50. Clean and inspect the exhaust manifolds. For additional information, Refer to «BRAKE SYSTEM-GENERAL INFORMATION»(ref-210119) .
51. Install the special tools on both ends of the cylinder head.
52. Remove the hydraulic lash adjusters.
53. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
54. 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 surface is normal.
55. 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).
56. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
57. Remove the bolts.
58. Remove the water pump from the cylinder block.
59. Remove the bolts and the A/C compressor.
60. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
61. Remove the bolts, the oil pan and the oil pan gasket.
62. Remove the bolts, the oil pump screen cover and tube and the spacer.
63. Remove the oil pump. Remove the bolts. Remove the oil pump.
64. Remove the bolts and the connecting rod caps. Rotate the crankshaft so that the connecting rod is a bottom dead center. Remove and discard the bolts.
65. Remove the piston and rod assembly. Using the special tool, guide the piston and rod assembly out of the cylinder.
66. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
67. Remove and discard the 12 cross-mounted bolts.
68. Remove and discard the bolts.
69. Remove the main bearing cap dowel pins.
70. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
71. Remove the crankshaft and the crankshaft main bearings from the cylinder block.

Cylinder Head

SPECIAL TOOL(S)

Scheme 1327

MATERIAL

MATERIAL SPECIFICATION

Piston

Material

MATERIAL SPECIFICATION

Scheme 1328

Scheme 1329

Scheme 1330

1. Remove the clips.
2. Remove the piston pin from the piston and connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .

Scheme 1331

Scheme 1332

Scheme 1333

1. Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.

SPECIAL TOOL(S)

Scheme 1334

MATERIAL

MATERIAL SPECIFICATION

Scheme 1335

Scheme 1336

Scheme 1337

Scheme 1338

Scheme 1339

Scheme 1340

Scheme 1341

Scheme 1342

Scheme 1343

Scheme 1344

Scheme 1345

Scheme 1346

Scheme 1347

Scheme 1348

Scheme 1349

Scheme 1350

Scheme 1351

Scheme 1352

Scheme 1353

Scheme 1354

Scheme 1355

Scheme 1356

Scheme 1357

Scheme 1358

Scheme 1359

Scheme 1360

Scheme 1361

Scheme 1362

Scheme 1363

Scheme 1364

Scheme 1365

Scheme 1366

Scheme 1367

Scheme 1368

Scheme 1369

Scheme 1370

Scheme 1371

Scheme 1372

Scheme 1373

Scheme 1374

Scheme 1375

Scheme 1376

Scheme 1377

Scheme 1378

Scheme 1379

Scheme 1380

1. Install the head gaskets over the dowel pins.
2. Loosely install cylinder head bolts.
3. Tighten the cylinder head bolts in three stages in the sequence shown. Stage 1: Tighten the bolts to 40 Nm (30 lb-ft). Stage 2: Tighten the bolts an additional 90 degrees. Stage 3: Tighten the bolts an additional 90 degrees.
4. Tighten the cylinder head bolts in three stages in the sequence shown. Stage 1: Tighten the bolts to 40 Nm (30 lb-ft). Stage 2: Tighten the bolts an additional 90 degrees. Stage 3: Tighten the bolts an additional 90 degrees.
5. Remove the lifting handles from both ends of the cylinder head.
6. Install the hydraulic lash adjusters in their original locations.
7. Using new gaskets, install the RH exhaust manifold. Tighten the nuts in the sequence shown. LH CYLINDER HEAD
8. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
9. Compress the tensioner plunger, using a vise.
10. Install a retaining clip on the tensioner to hold the plunger during installation.
11. Remove the tensioner from the vise.
12. 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.
13. Install the timing chain guides.
14. 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.
15. Position the crankshaft so the number one cylinder is at TDC with the special tool.
16. Remove the crankshaft holding tool.
17. Install the crankshaft sprocket, making sure the flange faces forward.
18. 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.
19. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
20. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
21. Remove the retaining clip from the LH timing chain tensioner.
22. Position the lower end of the RH (outer) 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.
23. 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.
24. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
25. Remove the retaining clip from the RH timing chain tensioner.
26. As a post-check, verify correct alignment of all timing marks.
27. Install the special tool between the valve spring coils to prevent valve stem seal damage.
28. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
29. Install the 10 spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
30. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
31. Position the balance shaft on the journals.
32. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
33. Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence shown.
34. Install the crankshaft sensor ring on the crankshaft.
35. 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.
36. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.
37. Tighten the engine front cover fasteners in sequence in three stages.
38. Loosely install the bolts, then tighten in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
39. Position the belt idler pulley and install the bolt.
40. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
41. Using the special tools, install the crankshaft front seal.
42. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
43. Use the special tool to install the crankshaft pulley.
44. Tighten the new crankshaft 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.
45. Position the water pump pulley on the water pump and install the bolts.
46. Position the power steering pump and install the bolts.
47. 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.
48. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
49. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
50. Tighten the bolts in the sequence shown.
51. 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.
52. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
53. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
54. Tighten the bolts in the sequence shown.
55. Position the oil level indicator tube.
56. Install the bolt attaching the oil level indicator tube to the rear of the engine.
57. Install the nut attaching the oil level indicator tube to the front of the engine.
58. Connect the crankcase vent tube to the valve cover.
59. Install the radio frequency interference capacitors.
60. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
61. Connect the CKP sensor electrical connector.
62. Connect the oil pressure switch electrical connector.
63. Connect the knock sensor electrical connector, if equipped.
64. Connect the RH radio frequency interference capacitor electrical connector.
65. Connect the CMP sensor electrical connector.
66. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
67. Install the cylinder block drain plugs.
68. Install the RH engine mount. Tighten the bolts to 63 Nm (46 lb-ft).
69. Install the special tool.
70. Install the special tool.
71. Install the special tool and remove the engine from the work stand.
72. Lower the engine onto wooden blocks.
73. Remove the special tool.
74. Remove the special tool.
75. Install the special tool and raise the engine.
76. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence shown.
77. Install the engine. For additional information refer to «ENGINE»(ref-210138-S20481162292005121300000) .

SPECIAL TOOL(S)

Scheme 1381

MATERIAL

MATERIAL SPECIFICATION

Scheme 1382

Scheme 1383

Scheme 1384

Scheme 1385

Scheme 1386

Scheme 1387

Scheme 1388

Scheme 1389

Scheme 1390

Scheme 1391

Scheme 1392

Scheme 1393

1. Position the engine in the vehicle and remove the Modular Engine Lift Bracket and the jack supporting the transmission.
2. Raise and support the vehicle.
3. Install and tighten the nuts.
4. Install the fuel tube line bracket and the remaining transmission to engine bolts.
5. Install and tighten the six new nuts retaining the torque converter.
6. Install the starter motor. For additional information, refer to «STARTERS - EXCEPT DIESEL»(ref-139515) .
7. Position the A/C compressor manifold assembly and install the bolt.
8. Install and tighten the nuts.
9. Connect the power steering pressure hose.
10. Install the oil cooler to the oil filter adapter and install the oil filter.
11. Position the oil cooler hoses and install the hose clamps.
12. Connect the lower radiator hose.
13. Lower the vehicle.
14. Connect the transmission wiring harness and the LH and RH heated exhaust gas oxygen sensor connectors.
15. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-210138-S04698938422005121300000) in this section.
16. Install the suction line to the accumulator.
17. Install the power steering reservoir hose at the power steering pump.
18. Connect the 16 and 42-pin connectors.
19. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
20. Install the upper and lower radiator supports, valance panel, radiator grille support and the radiator RH and LH air deflectors. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
21. Install the A/C condenser core. For additional information, refer to «AIR CONDITIONING»(ref-210171) .
22. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
23. Install the side marker lamps and headlamps. For additional information, refer to «EXTERIOR LIGHTING»(ref-210191) .
24. Install the engine air cleaner assembly and tubes.
25. Fill all fluids to the correct levels.
26. Connect the battery ground cable.
27. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
28. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .