Engine Mechanical - 3.5L: Overhaul Ford Edge I рестайлинг

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.

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1. Using the Valve Spring Compressors, remove the keys, retainer and spring.
2. Remove the valve from the cylinder head.
3. Remove and discard the valve stem seal.
4. Repeat the above steps for each valve. RH cylinder head
5. Remove and discard the Cylinder Head Temperature (CHT) sensor.

Assembly

All cylinder heads

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1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
2. Install the valve.
3. Using the Valve Spring Compressors, install the valve spring, retainer and key.
4. Repeat the above steps for each valve. RH cylinder head
5. Install a new CHT sensor. Tighten to 10 Nm (89 lb-in).

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin. Discard the 2 piston pin retainer clips.
3. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .

Scheme 263

1. Align the piston-to-connecting rod orientation marks and 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 new piston pin retaining clips in the piston. The piston pin retaining clip gap orientation must be toward the top or dome of piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston as shown in illustration. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location

SPECIAL TOOLS CHART 2, 200# Floor Crane, Fold Away 300-OTC1819E Alignment Pins 307-399 Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Eye, Engine Lift 303-1245 Handle 205-153 (T80T-4000-W) Hold Down, Secondary Chain 303-1530 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, Front Crankshaft Seal 303-1251 Installer, Rear Main Seal 303-1250 Installer, VCT Spark Plug Tube Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248

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MATERIAL SPECIFICATIONS

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Note. 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, may cause engine failure.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Note. If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

Note. The Differential Bearing Cone Installer is used to install the Variable Camshaft Timing (VCT) solenoid seals.

All vehicles

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1. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block face. The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
2. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4. 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 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing. Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3. Read the second letter of the engine block main bearing code and the second 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 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is "1". Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
4. Using the original connecting rod cap bolts, install the connecting rod caps and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure the connecting rod large end bore in 2 directions. Remove the bolts and the rod cap. Discard the connecting rod cap bolts.
6. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
7. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
8. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
9. Install the crankshaft onto the upper main bearings.
10. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
11. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.
12. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
13. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
14. Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.
15. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
16. Loosen the No. 4 main bearing cap bolts.
17. Tighten the main bearing bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 60 Nm (44 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
18. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
19. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
20. Prepare the connecting rod and cap. Insert the new bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap.
21. Before installing the pistons into the cylinder block, verify proper ring gap location. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location
22. Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
23. Seat the connecting rod on the crankshaft journal.
24. Install the connecting rod cap and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
25. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
26. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps. Stage 1: Tighten fasteners to 20 Nm (177 lb-in). Stage 2: Tighten fasteners an additional 180 degrees.
27. 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.
28. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
29. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
30. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
31. Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
32. 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.
33. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown in illustration to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
34. 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 in illustration.
35. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration, to 3 Nm (27 lb-in).
36. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration. 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).
37. 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).
38. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
39. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 45 degrees.
41. Install the bolt. Tighten to 10 Nm (89 lb-in).
42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 45 degrees.
43. Install the bolt. Tighten to 10 Nm (89 lb-in).
44. Install the valve tappets.
45. Install the upper intake manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
46. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
47. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
48. Position the crankshaft dowel pin in the 9 o'clock position.
49. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
50. Position the 4 camshaft seals gaps as shown in illustration.
51. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
52. Loosen the 4 camshaft caps bolts.
53. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
54. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-494554-S26509119222012081400000) .
55. Remove the 3 bolts and the RH valve train oil tube.
56. Rotate the RH camshafts to the TDC position as shown in illustration.
57. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
58. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
59. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
60. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
61. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
62. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
63. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
64. Position the 4 camshaft seals gaps as shown in illustration.
65. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
66. Loosen the 4 camshaft caps bolts.
67. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
68. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-494554-S26509119222012081400000) .
69. Remove the 3 bolts and the LH valve train oil tube.
70. Rotate the LH camshafts to the TDC position as shown in illustration.
71. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
72. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
73. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
74. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
75. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
76. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
77. Install the LH upper primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
78. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
79. Install the crankshaft timing chain sprocket.
80. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
81. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
82. Install the primary timing chain tensioner arm.
83. Reset the primary timing chain tensioner. Release the ratchet detent. Using a soft-jawed vise, compress the ratchet plunger. Align the hole in the ratchet plunger with the hole in the tensioner housing. Install a suitable lockpin.
84. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
85. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
86. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
87. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
88. Remove the RH Camshaft Holding Tool.
89. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
90. Remove the LH Camshaft Holding Tool.
91. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
92. Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
93. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
94. Install the Alignment Pins.
95. 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 4 inner bolt 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.
96. Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22. Tighten in sequence to 3 Nm (27 lb-in).
97. Remove the Alignment Pins.
98. Install the M6 engine front cover bolt.
99. Install the 3 M10 engine front cover bolts.
100. 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 illustration in 7 stages stated below: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in). Stage 4: Loosen bolt 26 one full turn. Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees. Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees. Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.
101. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
102. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
103. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
104. Using a new gasket, install the RH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
105. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
106. Install the 3 RH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in).
107. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
108. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
109. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
110. Install the 3 LH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in.)
111. Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
112. Install the EOP switch. Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
113. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
114. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
115. Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.
116. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
117. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
118. Install the 2 RH CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
119. Install the 2 LH CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
120. Install the cover and the pin-type retainer.
121. If equipped, install the block heater wiring harness onto the engine. Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees. Tighten the block heater to 40 Nm (30 lb-ft).
122. Install the LH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
123. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
124. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Front Wheel Drive (FWD) vehicles
125. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
126. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
127. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts. Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft). Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
128. Install the LH exhaust heat shield and the 3 bolts. Tighten to 12 Nm (106 lb-in).
129. Install the LH HO2S. Tighten to 48 Nm (35 lb-ft).
130. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
131. Position the 2 power steering hose brackets and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
132. Install the generator, the bolt and the nut. Tighten to 47 Nm (35 lb-ft).
133. Position the wiring harness onto the engine.
134. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
135. Attach the wiring harness retainer to the generator.
136. Connect the generator electrical connector.
137. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
138. Connect the A/C compressor electrical connector.
139. Connect the CKP sensor electrical connector.
140. Install the wiring harness grommet.
141. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
142. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
143. Install the ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
144. Connect the CHT sensor electrical connector.
145. Connect the KS electrical connector.
146. Connect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
147. Attach the wiring harness retainer.
148. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
149. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 2 wiring harness retainers.
150. Connect the HO2S and CMS electrical connectors. Attach the 2 wiring harness retainers to the RH valve cover.
151. Connect the 3 RH coil-on-plug electrical connectors.
152. Using a new gasket, install the intake manifold and the 7 bolts. Tighten in the sequence shown in illustration in 2 stages stated below. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
153. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
154. Connect the crankcase ventilation hose to the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
155. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
156. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Attach the pin-type retainer.
157. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Attach the wiring harness pin-type retainer.
158. Attach the wiring harness retainer to the intake manifold.
159. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector. Install the wiring harness retainer to the rear of the LH cylinder head.
160. Connect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
161. Attach the 2 wiring harness retainers.
162. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
163. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector. Attach the wiring harness connector pin-type retainer to the LH valve cover.
164. Attach the 2 wiring harness pin-type retainers.
165. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the wiring harness pin-type retainer.
166. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
167. Attach the wiring harness connector pin-type retainer to the LH valve cover.
168. Connect the 3 LH coil-on-plug electrical connectors.
169. Install the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
170. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
171. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
172. Using the Strap Wrench, 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.
173. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
174. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
175. If equipped, connect the block heater electrical connector and install the heat shield.
176. Install the Engine Lift Eye on the LH cylinder head.
177. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
178. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
179. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
180. Install the crankshaft sensor ring.
181. Install the flexplate and the 8 bolts. Tighten in the sequence shown in illustration to 80 Nm (59 lb-ft).

SPECIAL TOOLS CHART 2, 200# Floor Crane, Fold Away 300-OTC1819E Adjustable Grip Arm, 1735A 014-00001 Powertrain Lift 300-OTC1585AE Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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1. Align the transaxle to the engine.
2. Install the 5 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.
5. Install the Powertrain Lift and Adjustable Grip Arms.
6. Install the starter, the bolt and the stud bolt. Tighten to 27 Nm (20 lb-ft).
7. Connect the wiring harness retainer to the starter stud bolt.
8. Attach the starter motor wire terminals and install the 2 nuts. Tighten the starter B+ terminal nut to 12 Nm (106 lb-in). Tighten the starter S-terminal nut to 5 Nm (44 lb-in). Position the starter terminal boot over the starter terminal.
9. Connect the transmission control electrical connector. Attach the wiring harness retainer.
10. Connect the fuel supply tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
11. Connect the EVAP tube quick connect coupling to the purge valve. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Attach the EVAP tube retainer.
12. Raise the engine and transaxle assembly into the vehicle.
13. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
14. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
15. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (177 lb-in).
16. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten the bolt to 80 Nm (59 lb-ft). Tighten the 3 nuts to 63 Nm (46 lb-ft).
17. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
18. Connect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . All-Wheel Drive (AWD) vehicles
19. Using a small screwdriver, remove the compression seal and discard.
20. Using a soft-face hammer, install the new compression seal.
21. Position the PTU in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
22. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
23. Using a new gasket, install the RH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
24. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector. All vehicles
25. Using the Powertrain Lift, raise the subframe into the installed position.
26. Install the 2 middle subframe nuts. Tighten to 133 Nm (98 lb-ft).
27. Install the 2 front subframe nuts. Tighten to 133 Nm (98 lb-ft).
28. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
29. Position the subframe brace and loosely install the 2 bolts.
30. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
31. Tighten the 4 bolts to 90 Nm (66 lb-ft).
32. Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 9 Nm (80 lb-in).
33. Install the 3 RH lower bumper-to-subframe nuts. Tighten to 9 Nm (80 lb-in).
34. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
35. Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
36. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube. Tighten to 48 Nm (35 lb-ft).
37. Install the engine roll restrictor-to-subframe through bolt. Tighten to 115 Nm (85 lb-ft).
38. Install the roll restrictor heat shield and the 2 nuts. Tighten to 9 Nm (80 lb-in). AWD vehicles
39. 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). All vehicles
40. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 9 Nm (80 lb-in).
41. Connect the power steering cooler hose.
42. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
43. Install the 3 new torque converter bolts. Tighten to 55 Nm (41 lb-ft).
44. Install the inspection cover and the 2 fasteners.
45. Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
46. Connect the 2 transmission fluid cooler tubes.
47. Install the 2 secondary latches onto the transmission fluid cooler tubes.
48. Install the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-494576) .
49. Install the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
50. Install the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
51. Install the ground wire and bolt to the engine front cover. Tighten to 10 Nm (89 lb-in).
52. Install the oil level indicator.
53. Connect the wiring harness electrical connector. Attach the wiring harness retainer to the RH valve cover stud bolt.
54. Connect the 2 PCM electrical connectors. Attach the 2 wiring harness retainers to the stud bolts.
55. Connect the hose to the power steering reservoir.
56. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
57. Using a new O-ring seal, connect the A/C tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
58. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
59. Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
61. Connect the vacuum hose to the upper intake manifold.
62. Attach the 3 wiring harness retainers to the bracket and inner fender.
63. Connect the wiring harness electrical connector.
64. Attach the 2 wiring harness retainers to the stud bolt and bracket.
65. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in). Connect the wiring harness electrical connector.
66. Connect the power feed to the battery terminal and install the 2 nuts. Tighten to 8 Nm (71 lb-in). Connect the wiring harness electrical connector.
67. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
68. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
69. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
70. Install the intermediate shaft and the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
71. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
72. Fill the engine with clean engine oil.
73. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
74. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-494570) .
75. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
76. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.