DISASSEMBLY
All cylinder heads
Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
- Using the Valve Spring Compressors, remove the keys, retainer and spring.
- Remove the valve from the cylinder head.
- Remove and discard the valve stem seal.
- Repeat the above steps for each valve.
- Remove and discard the Cylinder Head Temperature (CHT) sensor.
ASSEMBLY
All cylinder heads
- Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
- Install the valve.
- Using the Valve Spring Compressors, install the valve spring, retainer and key.
- Repeat the above steps for each valve.
- Install a new CHT sensor. Tighten to 10 Nm (89 lb-in).
Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Camshaft Alignment Tool 303-1248 Engine Lifting Bracket 303-1245 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Rear Seal 303-1250 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)
| Item | Specification |
|---|---|
| Motorcraft High Performance Engine RTV Silicone TA-357 | WSE-M4G323-A6 |
| Motorcraft Metal Surface Prep ZC-31-A | |
| Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) | WSS-M97B51-A1 |
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent | WSS-M2C930-A |
| Silicone Gasket Remover ZC-30 | |
| Thread Sealant with PTFE TA-24 | WSK-M2G350-A2 |
Material
Scheme 19
| Item | Part Number | Description |
|---|---|---|
| 1 | 12C508 | Engine control harness |
| 2 | 9S455 | Upper intake manifold |
| 3 | 9F797 | Fuel rail |
| 4 | 9J444 | Upper intake manifold bracket |
| 5 | 9K461 | Lower intake manifold |
| 6 | 8A856 | Thermostat housing |
| 7 | 9N271 | Coolant tube |
| 8 | 9N271 | Knock sensor (KS) |
| 9 | 6010 | Cylinder block |
Scheme 20
| Item | Part Number | Description |
|---|---|---|
| 1 | 6A0003 | Engine mount bracket |
| 2 | W701512 | Crankshaft pulley bolt |
| 3 | N806165 | Crankshaft pulley washer |
| 4 | 6316 | Crankshaft pulley |
| 5 | 6700 | Crankshaft front seal |
| 6 | 6C086 | Engine front cover |
| 7 | 6268 | Timing chain |
| 8 | 6306 | Crankshaft timing sprocket |
| 9 | 6K254 | Primary timing chain tensioner |
| 10 | 6K255 | Primary timing chain tensioner arm |
| 11 | 6B274 | LH lower primary timing chain guide |
| 12 | 6M256 | RH primary timing chain guide |
| 13 | 6K297 | LH upper primary timing chain guide |
| 14 | 8501 | Coolant pump |
| 15 | 6010 | Cylinder block |
Scheme 21
| Item | Part Number | Description |
|---|---|---|
| 1 | 6675 | Oil pan |
| 2 | 6622 | Oil pump screen and pickup tube |
| 3 | 6621 | Oil pump |
| 4 | 6010 | Cylinder block |
| 5 | 6D327 | Crankshaft rear seal retainer |
| 6 | 12A227 | Crankshaft sensor ring |
| 7 | 6375 | Flexplate |
| 8 | 6881 | Oil filter adapter (without oil cooler) |
| 9 | 6881 | Oil filter adapter (with oil cooler) |
| 10 | 9278 | Engine oil pressure (EOP) switch |
Scheme 22
| Item | Part Number | Description |
|---|---|---|
| 1 | 6083 | LH cylinder head gasket |
| 2 | 6C261 | LH variable camshaft timing (VCT) housing |
| 3 | W12244 | LH exhaust manifold stud (6 required) |
| 4 | 6500 | Valve tappet (32 required) |
| 5 | 6050 | LH cylinder head |
| 6 | 6279 | LH camshaft bolt (2 required) |
| 7 | W710738 | LH exhaust camshaft sprocket washer |
| 8 | 6C524 | LH VCT assembly |
| 9 | 6256 | LH exhaust camshaft sprocket |
| 10 | 6C256 | LH secondary timing chain |
| 11 | 6A258 | LH camshaft cap (8 required) |
| 12 | 6A505 | LH valve cover |
| 13 | 6A267 | LH intake camshaft |
| 14 | 6A269 | LH exhaust camshaft |
| 15 | 6C271 | LH secondary timing chain tensioner |
Scheme 23
| Item | Part Number | Description |
|---|---|---|
| 1 | W712244 | RH exhaust manifold stud (6 required) |
| 2 | 6051 | RH cylinder head gasket |
| 3 | 6G004 | Cylinder head temperature (CHT) sensor |
| 4 | 14B485 | CHT sensor jumper harness |
| 5 | 6B288 | Camshaft position (CMP) sensor (2 required) |
| 6 | 6049 | RH cylinder head |
| 7 | 17A084 | Engine lift eye |
| 8 | 6C260 | RH variable camshaft timing (VCT) housing |
| 9 | 6279 | RH camshaft bolt (2 required) |
| 10 | W710738 | RH exhaust camshaft sprocket washer |
| 11 | 6256 | RH exhaust camshaft sprocket |
| 12 | 6C524 | RH VCT assembly |
| 13 | 6C256 | RH secondary timing chain |
| 14 | 6A266 | RH intake camshaft |
| 15 | 6A268 | RH exhaust camshaft |
| 16 | 12405 | Spark plug (6 required) |
| 17 | 6A258 | RH camshaft cap (8 required) |
| 18 | 6582 | RH valve cover |
| 19 | 12A375 | Coil-on-plug (6 required) |
| 20 | 6C270 | RH secondary timing chain tensioner |
| CAUTION | During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure. |
All vehicles
- Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
- Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
- Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
- Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
- Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
- Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
- Align the oil pan to the cylinder block and the A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
- Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
- Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown. Tighten the large bolts (1-14) to 24 Nm (18 lb-ft). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
- Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
- Install the coolant pump and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the knock sensor (KS) and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
- Using new O-ring seals, install the coolant tube.
- Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
- Install the bolt. Tighten to 10 Nm (89 lb-in).
- Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
- Install the bolt. Tighten to 10 Nm (89 lb-in).
- Position the crankshaft dowel pin in the 9 o'clock position.
- Install the valve tappets.
- Position the camshafts onto the RH cylinder head in the neutral position as shown.
- Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Position the camshafts onto the LH cylinder head in the neutral position as shown.
- Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to «Valve Clearance Check»(ref-292564-S39129138562008080400000) .
- Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Rotate the RH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
- Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
- Position the RH secondary timing assembly onto the camshafts.
- Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
- Remove the lockpin from the RH secondary timing chain tensioner.
- Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Rotate the LH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
- Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
- Position the LH secondary timing assembly onto the camshafts.
- Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
- Remove the lockpin from the LH secondary timing chain tensioner.
- Rotate the crankshaft clockwise 60 degrees to the top dead center position (crankshaft dowel pin at 11 o'clock).
- Install the crankshaft timing chain sprocket.
- Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
- Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Install the primary timing chain tensioner arm.
- Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
- Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
- As a post-check, verify correct alignment of all timing marks.
- Install new VCT housing seals.
- Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the special tools.
- Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
- Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
- Remove the special tools (alignment pins).
- Install the engine mount bracket and the 3 bolts.
- Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
- Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
- Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
- Using the special tools, install a new crankshaft front seal.
- Using the special tools, install the crankshaft pulley.
- Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 (lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
- Using the special tools, install new VCT solenoid and/or spark plug tube seals.
- Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
- Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
- Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
- Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
- If equipped, install a new oil cooler, new gaskets and the 6 bolts. Tighten to 10 Nm (89 lb-in).
- Install the EOP switch. Tighten to 18 Nm (13 lb-ft).
- Install the crankshaft position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
- Install LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
- Install and connect the cylinder head temperature (CHT) sensor jumper harness.
- Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
- Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
- Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
- Install the catalytic converter bracket and the 2 bolts. Tighten to 48 Nm (35 lb-ft).
- Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
- Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
- Install the cover and the pin-type retainer.
- Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
- Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
- Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
- Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
- Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
- Using a new gasket, install the RH catalytic converter and the 4 new nuts. Tighten to 40 Nm (30 lb-ft).
- Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
- Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
- Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
- Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
- Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (8 lb-ft).
- Install the power steering pump and the 3 bolts. Tighten to 24 Nm (18 lb-ft).
- Install the generator, the bolt and the nut. Tighten to 47 Nm (35 lb-ft).
- Position the wiring harness onto the engine.
- Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
- Attach the wiring harness retainer to the generator.
- Connect the generator electrical connector.
- Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
- Connect the A/C compressor electrical connector.
- Connect the CKP sensor electrical connector.
- Install the wiring harness grommet.
- Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
- Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
- Install the wiring harness retainer bolt on the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
- Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
- Connect the LH camshaft VCT solenoid electrical connector.
- Connect the 3 LH coil-on-plug electrical connectors.
- Connect the LH heated oxygen sensor (HO2S) electrical connector.
- Connect the LH catalyst monitor sensor electrical connector.
- Connect the LH CMP sensor electrical connector.
- Connect the CHT sensor electrical connector.
- Connect the 6 fuel injector electrical connectors (3 shown).
- Install the ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
- Connect the KS electrical connector.
- Connect the RH CMP sensor electrical connector.
- Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
- Connect the 3 RH coil-on-plug electrical connectors.
- Connect the RH VCT solenoid electrical connector.
- Connect the RH catalyst monitor sensor electrical connector.
- Connect the power steering pressure (PSP) switch electrical connector.
- Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the upper intake manifold support bracket and the 2 bolts (1 shown). Tighten to 10 Nm (89 lb-in).
- Connect the RH HO2S electrical connector.
- Attach the wiring harness retainers to the upper intake manifold.
- Connect the throttle body (TB) electrical connector.
- Connect the PCV hose to the PCV valve.
- If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
- If equipped, connect the block heater electrical connector and install the heat shield.
- Install the special tool on the LH cylinder head.
- Using the special tools, remove the engine from the stand.
- Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
- Using the special tools, install the new crankshaft rear seal.
- Install the crankshaft sensor ring.
- Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001
| Item | Specification |
|---|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent | WSS-M2C930-A |
Material
All vehicles
- Align the transaxle to the engine.
- Install the 5 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
- Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
- Using the special tools, position the engine and transaxle onto the lift table.
- Install the special tools.
- Install the starter, the bolt and the stud bolt. Tighten to 27 Nm (20 lb-ft).
- Connect the wiring harness retainer to the starter stud bolt.
- Attach the starter motor wire terminals and install the 2 nuts. Tighten to 12 Nm (9 lb-ft). Tighten to 5 Nm (44 lb-in). Position the starter terminal boot over the starter terminal.
- Raise the engine and transaxle assembly into the vehicle.
- Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
- Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
- Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (15 lb-ft).
- Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten to 63 Nm (46 lb-ft).
- Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
- Position the power transfer unit (PTU) in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
- Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
- Using a new gasket, install the RH catalytic converter and 4 new nuts.
- Install the 2 catalytic converter-to-bracket bolts. Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft). Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (15 lb-ft).
- Connect the RH catalyst monitor electrical connector.
- Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-292570) article.
- Position the RH halfshaft/intermediate shaft assembly in the PTU and in the steering knuckle and install the 2 bolts. Tighten to 40 Nm (30 lb-ft).
- Position the RH halfshaft/intermediate shaft assembly in the transaxle and in the steering knuckle and install the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
- Install the converter support bracket and the 2 bolts.
- Install the catalytic converter bracket bolt and the nut. Tighten the nut to 40 Nm (30 lb-ft). Tighten the bolt to 55 Nm (41 lb-ft).
- Tighten the 2 RH catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
- Install the LH halfshaft into the transaxle.
- If equipped, connect the oil cooler coolant hoses.
- Using the special tool, raise the subframe into the installed position.
- Install the 2 middle subframe nuts. Tighten to 133 Nm (98 lb-ft).
- Install the 2 front subframe nuts. Tighten to 133 Nm (98 lb-ft).
- Position the subframe support brackets in place and loosely install the 4 bolts.
- Install the 2 rear subframe bracket nuts. Tighten to 133 Nm (98 lb-ft).
- Tighten the 4 subframe support bracket bolts. Tighten to 90 Nm (66 lb-ft).
- Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 9 Nm (80 lb-in).
- Install the 3 RH lower bumper-to-subframe nuts. Tighten to 9 Nm (80 lb-in).
- Install the ball joints in the steering knuckles and install the pinch bolts. Tighten to 55 Nm (41 lb-ft).
- Position the stabilizer bar links in the lower control arms and install the nuts. Tighten to 90 Nm (66 lb-ft).
- Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
- Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
- Using a new banjo bolt and 2 new seals, install the power steering pressure (PSP) tube. Tighten to 48 Nm (35 lb-ft).
- Install the engine roll restrictor-to-subframe through bolt. Tighten to 103 Nm (76 lb-ft).
- Install the roll restrictor heat shield and the 2 nuts. Tighten to 11 Nm (8 lb-ft).
- Install a new RH front halfshaft nut. Tighten to 350 Nm (258 lb-ft).
- Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten to 70 Nm (52 lb-ft).
- Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 9 Nm (80 lb-in).
- Connect the power steering cooler hose.
- Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
- Install the 3 new torque converter bolts. Tighten to 55 Nm (41 lb-ft).
- Install the inspection cover and the 2 fasteners.
- Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
- Connect the 2 transmission fluid cooler tubes.
- Install the 2 secondary latches onto the transmission fluid cooler tubes.
- Install the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-292537) article.
- Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
- Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
- Install the 2 exhaust hangers and tighten the exhaust clamp. Tighten to 40 Nm (30 lb-ft).
- Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
- Install the ground wire and bolt to the engine front cover. Tighten to 10 Nm (89 lb-in).
- Attach the wiring harness retainer to the RH valve cover stud bolt.
- Install the oil level indicator.
- Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
- Connect the fuel hose routing clip to the transaxle stud.
- Connect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
- Connect the hose to the power steering reservoir.
- Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
- Using a new O-ring seal, connect the A/C tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
- If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
- Connect the transaxle control electrical connector.
- Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
- Attach the wiring harness retainer to the transaxle control cable bracket.
- Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
- Connect the upper evaporative emissions (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
- Connect the vacuum hose to the upper intake manifold.
- Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in). Attach the 2 wiring harness retainers to the cowl.
- Connect the power feed to the battery terminal and install the nut. Tighten to 8 Nm (71 lb-in).
- Connect the battery harness electrical connector.
- Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
- Install the engine air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
- Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
- Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
- Fill the engine with clean engine oil.
- Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
- Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-292528) article.
- Recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.