Contents Wiring diagrams Section: Engine Mechanical - 3.5L All sections

Piston — Part 2 Ford Edge I facelift

Engine Mechanical - 3.5L 80 illustrations ~4219 words

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  1. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
  2. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
  3. Position the 4 camshaft seals gaps as shown in illustration.
  4. 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.
  5. Loosen the 4 camshaft caps bolts.
  6. 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.
  7. 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) .
  8. Remove the 3 bolts and the RH valve train oil tube.
  9. Rotate the RH camshafts to the TDC position as shown in illustration.
  10. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  11. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
  12. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  13. 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.
  14. 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.
  15. 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. LH camshafts
  16. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
  17. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
  18. Position the 4 camshaft seals gaps as shown in illustration.
  19. 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.
  20. Loosen the 4 camshaft caps bolts.
  21. 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.
  22. 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) .
  23. Remove the 3 bolts and the LH valve train oil tube.
  24. Rotate the LH camshafts to the TDC position as shown in illustration.
  25. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
  26. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
  27. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
  28. 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.
  29. 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.
  30. 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. All camshafts
  31. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  32. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  33. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  34. Install the primary timing chain tensioner arm.
  35. 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.
  36. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  37. 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).
  38. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
  39. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
  40. Remove the RH Camshaft Holding Tool.
  41. 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.
  42. Remove the LH Camshaft Holding Tool.
  43. 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.
  44. 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.
  45. 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.
  46. Install the Alignment Pins.
  47. 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.
  48. Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22. Tighten in sequence to 3 Nm (27 lb-in).
  49. Remove the Alignment Pins.
  50. Install the M6 engine front cover bolt.
  51. Install the 3 M10 engine front cover bolts.
  52. 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.
  53. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  54. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
  55. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
  56. 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.
  57. 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).
  58. 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.
  59. Position the 2 power steering hose brackets and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
  60. Attach the wiring harness retainer.
  61. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
  62. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 2 wiring harness retainers.
  63. Connect the HO2S and CMS electrical connectors. Attach the 2 wiring harness retainers to the RH valve cover.
  64. Install the 3 RH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in).
  65. Connect the 3 RH coil-on-plug electrical connectors.
  66. 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.
  67. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
  68. Connect the crankcase ventilation hose to the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
  69. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
  70. 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.
  71. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Attach the wiring harness pin-type retainer.
  72. 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.
  73. 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).
  74. 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.
  75. Attach the 2 wiring harness retainers.
  76. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
  77. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector. Attach the wiring harness connector pin-type retainer to the LH valve cover.
  78. Attach the 2 wiring harness pin-type retainers.
  79. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the wiring harness pin-type retainer.
  80. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
  81. Attach the wiring harness connector pin-type retainer to the LH valve cover.
  82. Install the 3 LH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in.)
  83. Connect the 3 LH coil-on-plug electrical connectors.
  84. Install the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
  85. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
  86. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  87. 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.
  88. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
  89. Raise the engine and transaxle assembly into the vehicle.
  90. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  91. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  92. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (177 lb-in).
  93. 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).
  94. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
  95. 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) .
  96. Using the Powertrain Lift, raise the subframe into the installed position.
  97. Install the 2 middle subframe nuts. Tighten to 133 Nm (98 lb-ft).
  98. Install the 2 front subframe nuts. Tighten to 133 Nm (98 lb-ft).
  99. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
  100. Position the subframe brace and loosely install the 2 bolts.
  101. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
  102. Tighten the 4 bolts to 90 Nm (66 lb-ft).
  103. Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 9 Nm (80 lb-in).
  104. Install the 3 RH lower bumper-to-subframe nuts. Tighten to 9 Nm (80 lb-in).
  105. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
  106. Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
  107. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube. Tighten to 48 Nm (35 lb-ft).
  108. Install the engine roll restrictor-to-subframe through bolt. Tighten to 115 Nm (85 lb-ft).
  109. Install the roll restrictor heat shield and the 2 nuts. Tighten to 9 Nm (80 lb-in). AWD vehicles
  110. 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
  111. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 9 Nm (80 lb-in).
  112. Connect the power steering cooler hose.
  113. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  114. Connect the 2 transmission fluid cooler tubes.
  115. Install the 2 secondary latches onto the transmission fluid cooler tubes.
  116. Install the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-494576) .
  117. Install the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
  118. Install the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
  119. Install the ground wire and bolt to the engine front cover. Tighten to 10 Nm (89 lb-in).
  120. Install the oil level indicator.
  121. Connect the wiring harness electrical connector. Attach the wiring harness retainer to the RH valve cover stud bolt.
  122. Connect the 2 PCM electrical connectors. Attach the 3 wiring harness retainers.
  123. Connect the hose to the power steering reservoir.
  124. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
  125. Using a new O-ring seal, connect the A/C tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
  126. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
  127. Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
  128. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  129. Connect the vacuum hose to the upper intake manifold.
  130. Attach the 3 wiring harness retainers to the bracket and inner fender.
  131. Connect the wiring harness electrical connector.
  132. Attach the 2 wiring harness retainers to the stud bolt and bracket.
  133. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in). Connect the wiring harness electrical connector.
  134. 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.
  135. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
  136. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
  137. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
  138. Install the intermediate shaft and the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
  139. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
  140. Fill the engine with clean engine oil.
  141. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
  142. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-494570) .
  143. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
  144. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
ItemSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)WSS-M2C945-A

MATERIAL SPECIFICATIONS

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.

  1. Install the valve tappets.
  2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494554-S00420426842012081400000) .

SPECIAL TOOLS CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 898

Scheme 898: Valve Spring, Retainer and Seal

Scheme 899

Scheme 899
ItemSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)WSS-M2C945-A

MATERIAL SPECIFICATIONS

Scheme 900

Scheme 900
  1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
  2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
  3. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-494554-S34255165112012081400000) .
ItemSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)WSS-M2C945-A

MATERIAL SPECIFICATIONS

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, can cause engine failure.

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

Note. The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

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  1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration, in 5 stages stated below: 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.
  2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
  3. Install the valve tappets.
  4. Install and connect the CHT sensor jumper harness.
  5. 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).
  6. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
  7. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
  8. Install the upper intake manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  9. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  10. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
  11. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
  12. 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).
  13. 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).
  14. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  15. Install the LH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
  16. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
  17. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
  18. Install the ground wire and the bolt on the RH cylinder. Tighten to 10 Nm (89 lb-in).
  19. Install the 2 CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  20. Connect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
  21. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
  22. If equipped, position the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  23. Install the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494554-S00420426842012081400000) .
ItemSpecification
High Temperature Nickel Anti-Seize Lubricant XL-2
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)WSS-M2C945-A

MATERIAL SPECIFICATIONS

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, can cause engine failure.

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

Note. The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

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Scheme 945
  1. 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.
  2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
  3. Install the valve tappets.
  4. Install the LH upper primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
  5. 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).
  6. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
  7. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
  8. 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).
  9. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  10. Install the LH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
  11. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
  12. 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).
  13. Install the LH exhaust heat shield and the 3 bolts. Tighten to 12 Nm (106 lb-in).
  14. Install the LH HO2S. Tighten to 48 Nm (35 lb-ft).
  15. Install the generator, the bolt and the nut. Tighten to 47 Nm (35 lb-ft).
  16. Install the A/C compressor, the 2 bolts and the nut. Tighten to 25 Nm (18 lb-ft).
  17. Connect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
  18. Attach the wiring harness retainer to the generator.
  19. Connect the generator electrical connector.
  20. Connect the generator B+ cable and install the nut. Tighten to 7 Nm (150 lb-in).
  21. Connect the A/C compressor electrical connector.
  22. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector. Install the wiring harness retainer to the rear of the LH cylinder head.
  23. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
  24. Install the 2 LH CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  25. Connect the 2 LH CMP sensors electrical connectors.
  26. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
  27. If equipped, position the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  28. Install the LH camshafts. For additional information, refer to «CAMSHAFT»(ref-494554-S00420426842012081400000) .