Engine - 6.8L- E350 & E450: Other Ford Econoline E350 Super Duty

Engine Component View

The concept of modularity allows engine designs to share concepts and hardware. The following illustrations represent the 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.

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 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Refer to ENGINE SYSTEM-GENERAL INFORMATION for basic mechanical concerns or see INTRODUCTION - GASOLINE article for driveability concerns.

Material

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 592

Scheme 593

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
4. Disconnect the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
5. Remove the bolts and position the LH fuel charge wiring harness aside.
6. Disconnect the five fuel injector electrical connectors.
7. Disconnect the five ignition coil electrical connectors.
8. Disconnect the pushpin retainers from the powertrain control module (PCM) bracket.
9. Lift the fuel charging wiring off the valve cover studs.
10. Loosen the retaining nut.
11. Remove the bolt and position the oil level indicator and tube aside.
12. Disconnect the wiring retainers from the valve cover studs.
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. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

1. Apply instant gel 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 (Scheme 603)
5. Connect the wiring retainers on the valve cover studs.
6. Position back the oil level indicator and tube. Install the bolt.
7. Tighten the retaining nut.
8. Position the fuel charging wiring onto the valve cover studs.
9. Connect the pushpin retainers to the PCM bracket.
10. Position the LH fuel charge wiring harness and install the bolts.
11. Connect the five fuel injector electrical connectors.
12. Connect the five ignition coil electrical connectors.
13. Connect the PCV valve tube to the LH valve cover.
14. Install the engine air cleaner and engine air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380).
15. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379).
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
4. Disconnect the electrical connectors.
5. Disconnect the electrical connector position retainers, remove the nut, ground strap and mounting bracket.
6. Disconnect the oil fill tube from the RH valve cover.
7. Remove the bolt and the oil fill tube.
8. Disconnect the positive crankcase ventilation (PCV) electrical connector, tube and remove the PCV valve by rotating counterclockwise.
9. Disconnect the wiring harness retainers from the RH valve cover studs.
10. Remove the pushpin retainers and the splash shield.
11. Disconnect the A/C compressor and the crankshaft position (CKP) sensor connectors and remove the tie-strap.
12. Remove the transmission fluid filler tube nut.
13. Remove the retaining nut and position the transmission fluid indicator and tube aside.
14. Remove the stud bolts and position the RH fuel charge wiring harness aside.
15. Disconnect the five ignition coil electrical connectors.
16. Disconnect the five fuel injector electrical connectors. Lift the fuel charging wiring off the valve cover.
17. Disconnect the electronic throttle body (TB) electrical connector.
18. Position the fuel charging wiring into the passenger compartment.
19. Remove the five bolts and the RH ignition coils.
20. 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 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

1. Apply instant gel 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 (Scheme 617)
5. Install the five RH ignition coils and the bolts.
6. Position the fuel charging wiring harness on to the engine.
7. Connect the electronic TB electrical connector.
8. Position the RH fuel charge wiring harness and install the stud bolts.
9. Position back the transmission fluid indicator and tube. Install the retaining nut.
10. Connect the five fuel injector electrical connectors.
11. Connect the five ignition coil electrical connectors.
12. Install the transmission fluid filler tube nut.
13. Connect the A/C compressor and the CKP sensor connectors and install a tie-strap.
14. Position the splash shield and install the pushpin retainers.
15. Connect the wiring harness retainers to the RH valve cover studs.
16. Install the PCV valve by rotating clockwise and connect the PCV tube and electrical connector.
17. Connect the oil fill tube to the RH valve cover.
18. Install the oil fill tube support bracket bolt.
19. Position the mounting bracket, ground strap and install the nut. Connect the electrical connector retainers to the support bracket.
20. Connect the electrical connectors.
21. Install the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380).
22. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379).
23. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

Scheme 620

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-231358) .
4. Remove the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

Scheme 621

Scheme 622

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 «ACCESSORY DRIVE»(ref-231358) .
5. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .

MATERIAL SPECIFICATIONS

Scheme 623

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-231366-S40646428732006050800000) .
2. Using the special tool, remove the crankshaft front seal.

Scheme 624

Scheme 625

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-231366-S40646428732006050800000) .

MATERIAL SPECIFICATIONS

Scheme 626

Scheme 627

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Remove both of the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-231366-S05233704782006050800000) and «VALVE COVER - RH»(ref-231366-S19092288982006050800000) .
4. Remove the radiator. For additional information, refer to «ENGINE COOLING»(ref-231368) .
5. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-231368) .
6. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-231366-S17820143772006050800000) .
7. Remove the top bolts and the lower bolt and position the power steering pump aside.
8. Disconnect the wiring harness from the bracket.
9. Remove the retaining nut. Disconnect the tubes and remove the bracket.
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Remove the drain plug and drain the engine oil.
12. Remove the four front oil pan bolts.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Remove the bolt and the accessory drive belt idler pulley.
15. Remove the bolts.
16. 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 635

Scheme 636

Scheme 637

Scheme 638

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 (Scheme 638)
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 5 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 two stages, in the sequence see scheme 125 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
7. Connect the CKP sensor electrical connector.
8. Install the bracket and connect the tubes. Install the retaining nut.
9. Connect the wiring harness to the bracket.
10. Position the power steering pump and install the bolts.
11. Install the oil drain plug.
12. Install a new crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-231366-S17820143772006050800000).
13. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-231366-S05233704782006050800000) and «VALVE COVER - RH»(ref-231366-S19092288982006050800000).
14. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-231368).
15. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-231368).
16. Fill the engine with clean engine oil.
17. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 639

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000) .
2. Use the special tool to compress the valve springs and remove the camshaft roller followers.
3. Remove the bolts, the camshaft bearing caps and the camshaft from the cylinder block.

Scheme 640

Scheme 641

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the camshaft bearing caps in their original locations onto the cylinder head. Loosely install the 15 bolts.
3. Tighten the bolts in the sequence see scheme 164
4. Use the special tool to compress the valve springs and install the camshaft roller followers.
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000).

Scheme 642

Scheme 643

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Remove the four exhaust Y-pipe flange nuts.
4. Remove the 10 nuts, the exhaust manifold, and the exhaust manifold gasket. Discard the exhaust manifold gasket.
5. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .
6. To install, reverse the removal procedure. Install a new exhaust manifold gasket.

Scheme 644

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the nuts.
3. Remove the exhaust manifold nuts and the exhaust manifold. Discard the exhaust manifold gaskets.
4. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 645

Scheme 646

Scheme 647

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .
2. Drain the engine oil.
3. Disconnect the coolant hoses.
4. Remove the oil filter.
5. Remove the threaded insert and the oil cooler. Inspect the oil cooler.
6. To install, reverse the removal procedure. Fill the engine with clean engine oil before filling the cooling system.

MATERIAL SPECIFICATION

Scheme 648

1. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
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-231366-S34220912382006050800000) .
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.

MATERIAL SPECIFICATIONS

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
3. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Remove the retainers and the shield.
5. Remove the stud bolts and position the heater outlet tube aside.
6. Remove the two transmission-to-engine bolts.
7. Disconnect the oil fill tube from the RH valve cover.
8. Remove the bolt and the oil fill tube.
9. Assemble the special tools.
10. Install the special tools.
11. Install the special tool and support the engine.
12. Drain the engine oil and remove the oil filter.
13. Remove the nut and position the transmission fluid cooler tube support bracket aside.
14. Remove the RH and LH nuts retaining the front engine support insulators to the front engine support bracket.
15. Remove the flywheel inspection plate.
16. Using the special tool, raise the engine.
17. Remove the bolts and partially lower the oil pan.
18. 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.
19. 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 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

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 (Scheme 667)
4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations (Scheme 668)
5. Tighten the bolts in the sequence (Scheme 669) 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. Position the transmission fluid cooler tube support bracket and install the nut. Tighten to 12 Nm (9 lb-ft).
9. Install a new oil filter. Tighten to 16 Nm (12 lb-ft).
10. Install the engine support insulator nuts.
11. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
12. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten the studs to 40 Nm (30 lb-ft).
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-231366-S37433118952006050800000).
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-231368).
20. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368).

MATERIAL SPECIFICATIONS

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

1. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-231366-S34645306792006050800000) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Drain the engine oil.
5. Disconnect the coolant hoses.
6. Remove the oil filter.
7. Remove the threaded insert and the oil cooler. Inspect 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 671

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000) .
3. Remove the bolts and the oil pump.

Scheme 672

1. Clean and inspect the mating surfaces.
2. Position the oil pump and loosely install the bolts. Tighten the bolts in the sequence see scheme 212
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000).
4. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000).

Scheme 673

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-231384) .
2. Remove the bolts and the flexplate.

Scheme 674

1. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence see scheme 214
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-231384).

MATERIAL SPECIFICATION

Scheme 675

Scheme 676

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000) .
2. Use the special tools to remove the crankshaft rear oil slinger.
3. Use the special tools to remove the crankshaft rear seal.

Scheme 677

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-231366-S41513244252006050800000) .

MATERIAL SPECIFICATION

Scheme 678

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000) .
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-231366-S41608161492006050800000) .
5. Remove the bolts and the crankshaft rear seal retainer plate.

Scheme 679

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 see scheme 224
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-231366-S41608161492006050800000).
8. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000).

MATERIAL SPECIFICATIONS

Scheme 680

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
3. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Remove the retainers and the shield.
5. Remove the stud bolts and position the heater outlet tube aside.
6. Remove the two transmission-to-engine bolts.
7. Disconnect the oil fill tube from the RH valve cover.
8. Remove the bolt and the oil fill tube.
9. Assemble the special tools.
10. Install the special tools.
11. Install the special tool and support the engine.
12. Remove the RH and LH nuts retaining the front engine support insulators to the front engine support bracket.
13. Using the special tool, raise the engine.
14. Disconnect the oil pressure switch electrical connector.
15. Remove the oil pressure switch.
16. Remove the bolts and remove the engine mounts from the vehicle.

Scheme 681

1. Position the engine mounts and install the bolts.
2. Install the oil pressure switch.
3. Connect the oil pressure switch electrical connector.
4. Lower the engine and remove the special tools.
5. Install the engine support insulator nuts.
6. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
7. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten the studs to 40 Nm (30 lb-ft).
8. Connect the oil fill tube to the RH valve cover.
9. Install the oil fill tube support bracket bolt.
10. Install the transmission-to-engine bolts.
11. Install the shield and the retainers.
12. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
13. Install the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
14. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .

MATERIAL SPECIFICATIONS

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

Scheme 703

1. Remove the engine. For additional information, refer to «Engine»(ref-231366-S36221756232006050800000) .
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) 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-231364) .
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).

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

1. Remove the engine. For additional information, refer to «Engine»(ref-231366-S36221756232006050800000) .
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 «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .
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.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATION

Scheme 722

Scheme 723

Scheme 724

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-231364) .

Scheme 725

Scheme 726

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.

MATERIAL SPECIFICATIONS

Scheme 727

Scheme 728

Scheme 729

Scheme 730

1. Remove the four fuel rail bolts.
2. Remove the bolts from the fuel pressure regulator (FPR). Remove the fuel rail and injectors as an assembly.
3. Remove the fuel injectors from the fuel rail.
4. Remove and discard the O-ring seals from each fuel injector.
5. Separate the upper and lower intake manifolds. Remove the bolts. Discard the intake manifold gasket.
6. Using a metal surface prep, clean and inspect the upper and lower manifold internal passengers and mating surfaces.
7. Allow the upper and lower intake manifolds to dry completely.

Scheme 731

Scheme 732

1. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.
2. Tighten the bolts in two stages, using the sequence (Scheme 745) Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
3. Install new O-ring seals on each fuel injector.
4. Install the fuel injectors into the fuel rail.
5. Position the fuel rail. Install the bolts for the FPR sensor.
6. Install the four fuel rail bolts.

MATERIAL SPECIFICATIONS

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

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

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 chart, 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 3 and the Bearing Select Fit Chart (Scheme 751), Oversize Bearings chart 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 into the cylinder block and onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.
8. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.
9. Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.
10. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps 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 bolts.
12. Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
13. Tighten fasteners 1 through 12 in two stages, in the sequence (Scheme 753) Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
14. Tighten fasteners 13 through 24 in two stages, in the sequence see scheme 461 Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 90 degrees.
15. Using the special tools, install the piston and connecting rod assembly.
16. Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.
17. Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.
18. Tighten the connecting rod bolts in the sequence see scheme 463 Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
19. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
20. Install the oil filter adapter.
21. Install the front engine support insulators.
22. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence see scheme 465
23. Rotate the crankshaft to position the keyway at 12 o'clock.
24. Install the head gasket over the dowel pins.
25. Install the special tool.
26. Install the special tool.
27. Install the cylinder head on the head gasket. Remove the special tool and loosely install the bolt.
28. Remove the special tool.
29. Tighten the bolts in the sequence see scheme 472 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
30. Position the oil level indicator and install the nut attaching the oil level indicator tube to the front of the engine.
31. Install the bolt attaching the oil level indicator tube to the rear of the engine.
32. Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence see scheme 475
33. Compress the tensioner plunger, using a vise.
34. Install a retaining clip on the tensioner to hold the plunger in during installation.
35. Remove the tensioner from the vise.
36. If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.
37. Install the timing chain guides.
38. Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
39. Position the crankshaft with the special tool.
40. Remove the special tool.
41. Install the crankshaft sprocket, making sure the flange faces forward.
42. Install the lower end of the LH (inner) timing chain, aligning the timing marks.
43. Position the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.
44. Position the RH (outer) timing chain on the crankshaft sprocket.
45. Position the RH timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.
46. As a post-check, verify timing mark alignment.
47. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
48. Remove the retaining clip from the LH timing chain tensioner.
49. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
50. Remove the retaining clip from the RH timing chain tensioner.
51. Lubricate the balance shaft journals with clean engine oil.
52. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.
53. Position the balance shaft on the journals.
54. Align the chalk mark on the balance shaft with the camshaft timing mark (Scheme 764)
55. Install the bearing caps in their original locations and install the bolts. Tighten the bolts in the sequence see scheme 495
56. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
57. Install the special tool between the valve spring coils to prevent valve stem seal damage.
58. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
59. Position the crankshaft sensor ring.
60. Apply a bead of silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface as specified.
61. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.
62. Tighten the engine front cover fasteners in sequence in two stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
63. Install the belt idler pulley and tighten the bolt.
64. Position the oil pump screen 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.
65. 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.
66. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
67. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
68. Install the oil pan. Tighten the bolts in the sequence (Scheme 770) 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.
69. Install the oil drain plug.
70. Install the water 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 cylinder block. Install the coolant pump retaining bolts.
71. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
72. Using the special tool, install the crankshaft front seal.
73. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
74. Using the special tool, install the crankshaft pulley.
75. 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.
76. Position the coolant pump pulley on the coolant pump and install the bolts.
77. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
78. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
79. Position the valve covers.
80. Tighten the bolts in the sequence (Scheme 777)
81. Install the engine control sensor wiring harness. Connect all of the harness routing clips and connector retainers.
82. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
83. Connect the camshaft position (CMP) electrical connector.
84. Connect the RH radio frequency interference capacitor electrical connector.
85. Connect the knock sensor electrical connector, if equipped.
86. Connect the crankshaft position (CKP) sensor electrical connector.
87. Connect the oil pressure switch electrical connector.
88. Attach the special tool.
89. Remove the engine from the engine stand.
90. 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.
91. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
92. Install the retainer plate. Tighten the bolts in two stages. Stage 1: Tighten the retainer plate bolts to 10 Nm (89 lb-in), in the sequence see scheme 525 Stage 2: Tighten the oil pan bolts to 20 Nm (15 lb-ft), then tighten an additional 90 degrees.
93. Using the special tools, install a new crankshaft rear seal.
94. Using the special tools, install the crankshaft rear oil slinger.
95. Install the flexplate in the following sequence.

MATERIAL SPECIFICATION

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

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-231335) .
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 shift cable to the mounting bracket and shift linkage.
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 a new 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. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
20. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
21. Install and tighten the oil drain plug.
22. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the four upper transmission-to-engine bolts.
23. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
24. Insert the heater outlet tube over the new seals.
25. Install the heater outlet tube studs.
26. Position the transmission fluid filler tube in the vehicle. Connect the HO2S electrical connector.
27. Connect the hose to the heater outlet tube.
28. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
29. Connect the evaporative emission canister purge valve electrical connector.
30. 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.
31. Install the engine oil filler tube support strap bolt.
32. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
33. Connect the engine wiring harness electrical connectors.
34. Connect the powertrain control module (PCM) electrical connectors.
35. Connect the engine wiring harness to the PCM bracket.
36. Connect the lower radiator hose to the oil filter adapter coolant inlet.
37. Position the lower radiator support and install the twelve bolts.
38. Install the RH side of the headlamp dash panel junction wiring harness. Connect the electrical connector. Install the screw. Insert the routing clips.
39. Install the LH side of the headlamp dash panel junction wiring harness. Install the screw. Insert the routing clips.
40. Position the RH and LH air deflectors and install the pin-type retainers.
41. Position the upper radiator support and install the eight bolts.
42. Connect the horn electrical connector.
43. Connect the front impact severity sensor electrical connector.
44. If equipped, connect the air temperature sensor electrical connector.
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 cutoff 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. Using the special tool, 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-231417) .
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-231425) .
64. Fill the engine with clean engine oil.
65. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
66. Fill all fluids to the correct levels. Fill the transmission with clean transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(ref-231385) . Fill the power steering system with clean fluid. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-231357) .
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-231392) .

MATERIAL SPECIFICATIONS

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

1. Install the head gaskets over the dowel pins.
2. Install the special tool.
3. Remove the special tool and loosely install cylinder head bolts.
4. Tighten the cylinder head bolts in three stages in the sequence see scheme 590 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. Tighten the cylinder head bolts in three stages in the sequence see scheme 591 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.
6. Remove the lifting handles from both ends of the cylinder head.
7. Install the hydraulic lash adjusters in their original locations.
8. Using new gaskets, install the RH exhaust manifolds. Tighten the nuts in the sequence see scheme 594
9. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence see scheme 595
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger 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. Preposition 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 outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
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 10 spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
31. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
32. Position the balance shaft on the journals.
33. It may be necessary to use an inspection mirror to see the marks. Align the chalk mark on the balance shaft with the camshaft timing mark see scheme 616
34. Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence see scheme 617
35. Install the crankshaft sensor ring on the crankshaft.
36. 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 see scheme 619
37. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.
38. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 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).
39. Loosely install the bolts, then tighten in two stages, in the sequence see scheme 622 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
40. Position the belt idler pulley and install the bolt.
41. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
42. Using the special tools, install the crankshaft front seal.
43. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
44. Use the special tool to install the crankshaft pulley.
45. 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.
46. Position the coolant pump pulley on the coolant pump and install the bolts.
47. Position the power steering pump and install the bolts.
48. Apply instant gel adhesive completely around the gasket groove in the LH 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 LH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence see scheme 634
52. Apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
53. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
54. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
55. Tighten the bolts in the sequence see scheme 638
56. Position the oil level indicator tube.
57. Install the bolt attaching the oil level indicator tube to the rear of the engine.
58. Install the nut attaching the oil level indicator tube to the front of the engine.
59. Connect the crankcase vent tube to the valve cover.
60. Install the radio frequency interference capacitors.
61. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
62. Connect the crankshaft position (CKP) sensor electrical connector.
63. Connect the oil pressure switch electrical connector.
64. Connect the knock sensor electrical connector, if equipped.
65. Connect the RH radio frequency interference capacitor electrical connector.
66. Connect the camshaft position (CMP) sensor electrical connector.
67. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
68. Install the cylinder block drain plugs.
69. Install the RH engine mount. Tighten the bolts to 63 Nm (46 lb-ft).
70. Install the special tool.
71. Install the special tool.
72. Install the special tool and remove the engine from the work stand.
73. Lower the engine onto wooden blocks.
74. Remove the special tool.
75. Remove the special tool.
76. Install the special tool and raise the engine.
77. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence see scheme 657
78. Install the engine. For additional information refer to «Engine»(ref-231366-S03436327682006050800000).