Engine Mechanical - 3.0L (4V): Other Ford Escape I рестайлинг 2

Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION - GASOLINE MODELS .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors

1. are mounted between the fuel rail and the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the chains are driven by sprockets that are located on the crankshaft, just in front of the oil pump.

Variable Camshaft Timing (VCT) System

The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance, engine idle quality and exhaust emissions.

PCV System

All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Cooling System

The engine cooling system includes the following

1. Radiator
2. Dual electric fan assemblies
3. Degas bottle (aids in maintaining the correct volume of engine coolant)
4. Coolant thermostat
5. Coolant hoses
6. Coolant pump housing

Scheme 484

For basic engine mechanical concerns, refer to ENGINE SYSTEM-GENERAL INFORMATION . For driveability concerns, refer to the INTRODUCTION - GASOLINE MODELS .

Upper Intake Manifold

Upper Intake Manifold (View 1 of 2)

Scheme 485

PART NUMBER DESCRIPTION

Upper Intake Manifold (View 2 of 2)

Scheme 486

PART NUMBER DESCRIPTION

Material

MATERIAL SPECIFICATIONS

LH Valve Cover (View 1 of 3)

Scheme 487

PART NUMBER DESCRIPTION

LH Valve Cover (View 2 of 3)

Scheme 488

PART NUMBER DESCRIPTION

LH Valve Cover (View 3 of 3)

Scheme 489

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

RH Valve Cover (View 1 of 2)

Scheme 490

PART NUMBER DESCRIPTION

RH Valve Cover (View 2 of 2)

Scheme 491

PART NUMBER DESCRIPTION

Lower End Components - Exploded View

Crankshaft Pulley and Front Seal

Scheme 492

PART NUMBER DESCRIPTION

Flexplate and Rear Seal

Scheme 493

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

Scheme 494

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-344111) .
3. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

MATERIAL SPECIFICATIONS

Scheme 495

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-344117-S23386802722009101600000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal.

Scheme 496

1. Apply clean engine oil to the seal lip and seal bore before installing the seal.
2. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-344117-S23386802722009101600000) .

MATERIAL SPECIFICATIONS

Scheme 497

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-344117-S31782929412009101600000) .
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.

MATERIAL SPECIFICATIONS

Engine Front Cover (View 1 of 3)

Scheme 498

PART NUMBER DESCRIPTION

Engine Front Cover (View 2 of 3)

Scheme 499

PART NUMBER DESCRIPTION

Engine Front Cover (View 3 of 3)

Scheme 500

PART NUMBER DESCRIPTION

Valve Train Components - Exploded View

LH Side Roller Follower, Hydraulic Lash Adjuster and Valve Spring

Scheme 501

PART NUMBER DESCRIPTION

LH Side Intake and Exhaust Camshafts

Scheme 502

PART NUMBER DESCRIPTION

Coolant Pump Belt and Pulley

Scheme 503

PART NUMBER DESCRIPTION

RH Side Roller Follower, Hydraulic Lash Adjuster and Valve Spring

Scheme 504

PART NUMBER DESCRIPTION

RH Side Intake and Exhaust Camshaft

Scheme 505

PART NUMBER DESCRIPTION

Scheme 506

Scheme 507

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000) .
3. Remove the 3 bolts and the LH camshaft phaser and sprocket. Tighten to 18 Nm (159 lb-in).
4. Remove the 3 bolts and the RH camshaft phaser and sprocket. Tighten to 18 Nm (159 lb-in).
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 508

Scheme 509

1. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-344111).
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000).
3. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
4. Using the Oil Seal Remover, remove and discard the camshaft oil seal.
5. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
6. Verify the LH camshafts are in the neutral position.
7. Remove the 3 bolts and the LH camshaft phaser and sprocket.
8. If necessary, mark the camshaft bearing cap position and orientation as shown in the (Scheme 514).
9. Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (1L and 5L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.

Scheme 510

Scheme 511

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Scheme 513

Scheme 514

Scheme 515

1. Position the camshaft phaser and sprocket onto the intake camshaft. Install the 3 bolts finger-tight.
2. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown.
3. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
4. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
5. Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
6. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
7. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump Pulley Installer, install the camshaft oil seal.
9. Install the Camshaft Pulley Installer in the camshaft as shown in the see scheme 80. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
10. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the see scheme 81. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
11. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000).
12. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-344111).

MATERIAL SPECIFICATIONS

Scheme 516

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000).
2. Verify the RH camshafts are in the neutral position.
3. Remove the 3 bolts and the RH camshaft phaser and sprocket.
4. If necessary, mark the camshaft bearing cap position and orientation as shown in the (Scheme 522).
5. Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.

Scheme 517

Scheme 518

Scheme 519

1. Position the RH camshaft phaser and sprocket onto the intake camshaft. Install the 3 bolts finger-tight.
2. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown.
3. Install the camshaft bearing caps. Loosely install the bolts.
4. Install the camshaft bearing thrust caps. Loosely install the bolts.
5. Tighten the RH camshaft bearing cap bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
6. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
7. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000) .

MATERIAL SPECIFICATIONS

Scheme 520

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-344117-S21632177392009101600000) and «VALVE COVER - RH»(ref-344117-S36154400012009101600000) .
3. Remove the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .
4. Remove the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the roller follower.
6. Using the Valve Spring Compressor, remove the roller followers.
7. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 521

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-344117-S32120061392009101600000) .
2. Pressurize the cylinder using compressed air.
3. Using the Valve Spring Compressor, remove the key, retainer and the valve spring.
4. Remove the valve seal.

MATERIAL SPECIFICATIONS

Scheme 522

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

LH Cylinder Head

Scheme 523

PART NUMBER DESCRIPTION

Upper Radiator Support Brackets

Scheme 524

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 525

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

Oil Level Indicator and Tube

Scheme 526

PART NUMBER DESCRIPTION

Upper Radiator Support Brackets

Scheme 527

PART NUMBER DESCRIPTION

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.

Note. For additional information, refer to the exploded view under the Assembly procedure.

All vehicles

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1. Remove the bolts and the flexplate.
2. Remove the engine-to-transaxle separator plate.
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
6. Disconnect the electronic throttle control electrical connector.
7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
9. Detach the wiring harness retainer from the upper intake manifold.
10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
11. Disconnect the RH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers. Front Wheel Drive (FWD) vehicles
12. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
13. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
14. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
15. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
16. Disconnect the fuel injector wiring harness electrical connector.
17. Disconnect the LH VCT electrical connector.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
19. Disconnect the LH HO2S electrical connector.
20. Disconnect the 3 LH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers.
21. Remove the nut and the B+ wire from the generator.
22. Detach the 2 wiring harness retainers. Remove the B+ harness from the engine.
23. Remove the EGR tube fitting from the EGR valve.
24. Remove the 2 upper intake manifold bracket bolts (1 shown).
25. Remove the 7 bolts and the upper intake manifold. Remove and discard the gaskets.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.
28. Remove the 6 bolts and the 6 coil-on-plugs. FWD vehicles
29. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
30. Remove the 3 bolts and the RH heat shield.
31. Remove the 3 nuts and the RH catalytic converter. Discard the nuts and gasket. All vehicles
32. Remove the 6 RH exhaust manifold nuts and the manifold. Discard the nuts and gasket.
33. Remove and discard the 6 RH exhaust manifold studs.
34. Remove the bolt, 2 nuts and the generator.
35. Remove the 3 bolts and the A/C compressor bracket.
36. Remove the 3 bolts and the LH heat shield.
37. Remove the stud bolt and the oil level indicator and tube. Remove and discard the O-ring seal.
38. Remove the 6 nuts, the LH catalytic converter and the gasket. Discard the gasket and nuts.
39. Remove and discard the 6 LH exhaust manifold studs.
40. Remove the EOP switch and, if equipped, the block heater.
41. Remove and discard the oil filter.
42. Position the Stretchy Belt Remover under the coolant pump belt as shown.
43. With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
44. Remove the coolant pump belt. Fold the Stretchy Belt Remover over the top of the coolant pump belt. In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
45. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
46. Remove the 5 coolant pump housing bolts.
47. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
48. Remove the nut and the radio interference capacitor.
49. Remove the bolts and the RH valve cover. Discard the gasket.
50. Remove the bolts and the LH valve cover. Discard the gasket.
51. Remove the 15 bolts and the oil pan. Discard the gasket.
52. Remove the 2 bolts and the oil pump screen and pickup tube.
53. Remove and discard the O-ring seal.
54. Remove the oil pan baffle. Remove the 4 M6 oil pan baffle nuts. Remove the 4 M8 oil pan baffle nuts.
55. Remove the 3 bolts and the accessory drive belt tensioner.
56. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
57. Using the 3 Jaw Puller, remove the crankshaft pulley.
58. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
59. Remove the 2 bolts and the LH VCT.
60. Remove the 2 bolts and the RH VCT.
61. Remove the 14 bolts, 2 stud bolts and the engine front cover. Discard the gaskets.
62. Remove the LH and RH spark plugs.
63. Remove the ignition pulse wheel.
64. Install the crankshaft pulley bolt and washer.
65. Rotate the crankshaft clockwise to position the crankshaft key way in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
66. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
67. Verify that the RH camshafts are in the neutral position.
68. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
69. Remove the 2 bolts and the RH timing chain guide. Remove the RH timing chain from the engine.
70. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
71. Verify the LH camshafts are in the neutral position.
72. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
73. Remove the 2 bolts and the LH timing chain guide. Remove the LH timing chain from the engine.
74. Remove the crankshaft pulley bolt and the crankshaft sprocket.
75. Remove the 4 bolts in the sequence shown. Remove the oil pump.
76. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
77. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
78. Verify the LH camshafts are in the neutral position.
79. Remove the 3 bolts and the LH camshaft phaser and sprocket.
80. Remove and discard the VCT system oil filter screen from the LH camshaft.
81. If necessary, mark the camshaft bearing cap position and orientation as shown in the see scheme 259.
82. Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (1L and 5L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
83. Verify the RH camshafts are in the neutral position.
84. Remove the 3 bolts and the RH camshaft phaser and sprocket.
85. Remove and discard the VCT system oil filter screen from the RH camshaft.
86. If necessary, mark the camshaft bearing cap position and orientation as shown in the see scheme 264.
87. Loosen the bolts evenly in the sequence shown. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
88. Remove the LH and RH camshaft roller followers. Mark the location of the roller followers, using a permanent-type marker.
89. Remove the hydraulic lash adjusters.
90. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the bolts and the gaskets.
91. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
92. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060).
93. Remove the bolts and the oil separator cover. Discard the gasket.
94. Remove the crankshaft key.
95. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer' s instructions.
96. Remove the connecting rod cap bolts and cap. Discard the connecting rod cap bolts.
97. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
98. Remove the engine block from the stand and place on a workbench.
99. Remove the bolts and studs in the indicated sequence. Discard the lower cylinder block bolts. Remove the lower cylinder block.
100. Remove the crankshaft rear main seal. Remove the crankshaft.
101. Remove the crankshaft thrust bearing from the cylinder block.
102. Remove the bearings from the lower cylinder block.
103. Remove the crankshaft main bearings from the cylinder block.
104. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060).

MATERIAL SPECIFICATIONS

Scheme 587

PART NUMBER DESCRIPTION

MATERIAL SPECIFICATIONS

Lower Engine Block (View 1)

Scheme 588

PART NUMBER DESCRIPTION

Lower Engine Block (View 2)

Scheme 589

PART NUMBER DESCRIPTION

Cylinder Heads and Intake Manifolds

Scheme 590

PART NUMBER DESCRIPTION

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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 oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

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 .

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 rear face. The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2. The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
6. Install the crankshaft key.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.
9. Apply gasket and sealant to the cylinder block as shown.
10. Position the lower cylinder block and install the new bolts and new studs. Tighten the bolts and studs in the sequence shown in 4 stages. Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees. Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
11. 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 with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
13. Install the engine-to-transaxle separator plate.
14. Position the flexplate and install the bolts. Tighten to 80 Nm (59 lb-ft).
15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores. Measure the cylinder block bore diameter. Mark the outside of the block with the appropriate number(s) to identify bore grade size. Choose the correct piston grade size for the cylinder bore.
17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
18. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft).
19. Install the crankcase cover, a new gasket and the bolts. Tighten to 10 Nm (89 lb-in).
20. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
21. Install the crankshaft pulley bolt and rotate the crankshaft key way to the 11 o'clock position to locate Top Dead Center (TDC).
22. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
23. Apply clean engine oil to the LH and RH camshaft roller followers.
24. Install the LH and RH camshaft roller followers.
25. Install the new LH and RH oil filter screens in the intake camshafts.
26. Position the camshaft phaser and sprockets onto the intake camshafts. Install the 3 bolts finger-tight.
27. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown.
28. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
29. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
30. Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
31. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
32. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
33. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
34. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown.
35. Install the camshaft bearing caps. Loosely install the bolts.
36. Install the camshaft bearing thrust caps. Loosely install the bolts.
37. Tighten the RH camshaft bearing cap bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
38. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
39. Position the oil pump and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
40. Remove the crankshaft pulley bolt.
41. Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
42. Position the chain tensioner in a soft-jawed vise.
43. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
44. Slowly compress the timing chain tensioner.
45. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
46. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
47. Position the LH timing chain and guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
48. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
49. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
50. Verify that the RH camshafts are correctly positioned.
51. Install the RH timing chain and chain guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
52. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
53. Remove the LH and RH timing chain tensioner piston retaining wires.
54. Rotate the crankshaft counterclockwise 120 degrees to TDC.
55. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
56. Remove the crankshaft pulley bolt and washer.
57. Install the ignition pulse wheel.
58. Install the LH and RH spark plugs. Tighten to 15 Nm (133 lb-in).
59. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface prep and install new gaskets.
60. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
61. Position the front cover and install the bolts and stud bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
62. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid. Tighten to 10 Nm (89 lb-in).
63. Install the 2 bolts and the RH VCT solenoid. Tighten to 10 Nm (89 lb-in).
64. Apply clean engine oil to the seal lip and seal bore before installing the seal.
65. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
66. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
68. Install the bolt and washer. Tighten the bolt 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.
69. Install the belt tensioner and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
70. Install the 8 nuts and the oil pan baffle in the following sequence. Tighten the 4 M6 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten an additional 45 degrees. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten an additional 45 degrees.
71. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate the O-ring seal with clean engine oil.
72. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the 2 bolts and tighten to 10 Nm (89 lb-in).
73. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
74. Position the LH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
75. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
76. Position the RH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
77. Install the radio interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
78. Position the coolant pump housing and attach the coolant hose. Tighten the clamp to 7 Nm (62 lb-in).
79. Install the 5 coolant pump housing bolts. Tighten to 10 Nm (89 lb-in).
80. Install the Camshaft Pulley Installer in the camshaft as shown in the see scheme 355. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
81. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the see scheme 356. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
82. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
83. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
84. Lubricate the O-ring seal with clean engine oil and install the oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
85. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater. Tighten the EOP switch to 14 Nm (124 lb-in). Tighten the block heater to 21 Nm (15 lb-ft).
86. Install 6 new LH catalytic converter studs. Tighten to 12 Nm (106 lb-in).
87. Install a new gasket and the LH catalytic converter and 6 new nuts. Tighten in the sequence shown to 20 Nm (177 lb-in).
88. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
89. Position the oil level indicator and tube and install the stud bolt. Tighten to 10 Nm (89 lb-in).
90. Install the 3 bolts and the LH heat shield. Tighten to 10 Nm (89 lb-in).
91. Install the 3 bolts and the A/C compressor bracket. Tighten to 25 Nm (18 lb-ft).
92. Position the generator and install the bolt and 2 nuts. Tighten to 47 Nm (35 lb-ft).
93. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
94. Install a new gasket and the RH exhaust manifold and new nuts. Tighten the nuts in 2 stages in the sequence shown. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in). FWD vehicles
95. Install a new gasket and the RH catalytic converter and the 3 new nuts. Tighten to 40 Nm (30 lb-ft).
96. Install the 3 bolts and the RH heat shield. Tighten to 10 Nm (89 lb-in).
97. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
98. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. Install the 6 coil-on-plugs and the bolts. Tighten to 6 Nm (53 lb-in).
99. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
100. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
101. Install the 4 bolts and the fuel rail and injectors assembly. Tighten to 10 Nm (89 lb-in).
102. Position the upper intake manifold and install the 7 bolts. Tighten the bolts in 2 stages in the sequence shown. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
103. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown), then tighten all the bolts. Tighten to 10 Nm (89 lb-in).
104. Install the EGR tube fitting in the EGR valve. Tighten to 40 Nm (30 lb-ft).
105. Position and attach the 3 B+ wiring harness retainers.
106. Install the B+ wire and nut on the generator. Tighten to 8 Nm (71 lb-in).
107. Connect the 3 LH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers.
108. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
109. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
110. Connect the LH VCT electrical connector.
111. Connect the fuel injector wiring harness electrical connector.
112. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
113. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
114. Connect the RH VCT electrical connector.
115. Connect the RH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers. FWD vehicles
116. Connect the RH HO2S electrical connector. All vehicles
117. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
118. Attach the wiring harness retainer to the upper intake manifold.
119. Connect the EGR regulator electrical connector and attach the wiring retainer.
120. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
121. Connect the electronic throttle control electrical connector.
122. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
123. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.

MATERIAL SPECIFICATIONS