Engine Mechanical - 3.0L (4V): Removal & Installation Ford Escape II

Removal

1. Remove the Air Cleaner (ACL) outlet pipe and the ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(ref-344099) .
2. Remove the EGR tube fitting from the EGR valve.
3. Disconnect the electronic throttle control electrical connector.
4. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
5. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
6. Disconnect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube from the upper intake manifold.
7. Detach the engine control wiring harness retainer from the upper intake manifold.
8. Disconnect the PCV tube from the upper intake manifold.
9. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
10. Remove the 2 upper intake manifold support bracket bolts from the upper intake manifold.
11. Remove the 7 bolts and the upper intake manifold. Remove and discard the gaskets.

Scheme 346

1. 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.
2. Install the 2 upper intake manifold support bracket bolts. Tighten to 10 Nm (89 lb-in).
3. Connect the MAP electrical connector and attach the wiring retainer.
4. Connect the PCV tube to the upper intake manifold.
5. Attach the engine control wiring harness retainer to the upper intake manifold.
6. Connect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
7. Connect the EGR regulator electrical connector and attach the wiring retainer.
8. Connect the EVAP canister purge valve electrical connector.
9. Connect the electronic throttle control electrical connector.
10. Install the EGR tube fitting to the EGR valve. Tighten to 40 Nm (30 lb-ft).
11. Install the ACL outlet pipe and the ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(ref-344099) .

Scheme 347

PART NUMBER DESCRIPTION

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
3. Remove the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 3.0L (4V)»(ref-344123) .
4. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.

Scheme 348

1. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 3.0L (4V)»(ref-344123) .
3. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .

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. Remove the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .
2. Detach the upper radiator hose from the 2 retainers on the cooling fan shroud and position the hose aside.
3. Detach the 2 wiring retainers from the valve cover.
4. Detach the 2 wiring retainers from the valve cover stud bolts.
5. Disconnect the Variable Camshaft Timing (VCT) electrical connector.
6. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
7. Remove the 8 bolts, 6 stud bolts and the valve cover. Remove and discard the gasket.

Scheme 349

1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
2. Position the valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Connect the HO2S electrical connector.
4. Connect the VCT electrical connector.
5. Attach the 2 wiring retainers to the valve cover stud bolts.
6. Attach the 2 wiring retainers to the valve cover.
7. Attach the upper radiator hose to the 2 retainers on the cooling fan shroud.
8. Install the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .

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. Remove the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .
2. Detach the 3 main engine control wiring harness retainers from the valve cover stud bolts.
3. Detach the 3 main engine control wiring harness retainers from the valve cover.
4. Disconnect the Variable Camshaft Timing (VCT) electrical connector.
5. Detach the Crankshaft Position (CKP) wiring harness retainer from the stud.
6. Remove the 11 bolts, 3 stud bolts and the valve cover. Remove and discard the gasket.

Scheme 350

1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
2. Position the valve cover and install the 11 bolts and 3 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Attach the CKP wiring harness retainer on the stud.
4. Connect the VCT electrical connector.
5. Attach the 3 main engine control wiring harness retainers to the valve cover.
6. Attach the 3 main engine control wiring harness retainers to the valve cover stud bolts.
7. Install the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .

Installation

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Apply silicone gasket and sealant to the end of the keyway slot.
3. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
4. 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.
5. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-344111) .

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-344057) .
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

1. Using the Crankshaft Rear Main Oil Seal Installer Bolts and the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-344117-S31782929412009101600000) .

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.

Scheme 351

Scheme 352

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
4. Remove the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-344117-S37384209342009101600000) and «CRANKSHAFT FRONT SEAL»(ref-344117-S36993205562009101600000) .
5. Remove the generator bolt and the 2 nuts.
6. Remove the stud and position the generator away from the engine.
7. Remove the 3 bolts and the accessory drive belt tensioner.
8. Detach the wiring harness retainer from the engine front cover stud bolt.
9. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
10. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
11. Remove the LH and RH Variable Camshaft Timing (VCT) oil control solenoids. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(ref-344105) .
12. Remove the engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-344117-S39011620802009101600000) .
13. Remove the 2 oil pan-to-front cover bolts.
14. Remove the 14 bolts, 2 stud bolts and the engine front cover. Remove and discard the gaskets.

Scheme 353

1. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface prep and install new gaskets.
2. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
3. Position the engine front cover and install the bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft). PART NUMBER DESCRIPTION Item Part Number Description 1 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 2 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 3 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64 4 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20/M8 x 1.25 x 47.5 5 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 6 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 7 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 8 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 9 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 10 W708221 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 11 W708221 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 12 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 13 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20/M8 x 1.25 x 47.5 14 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64 15 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 16 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5
4. Install the 2 oil pan-to-front cover bolts. Tighten to 25 Nm (18 lb-ft).
5. Remove the oil pan drain plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
6. Install the engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-344117-S39011620802009101600000) .
7. Install the LH and RH VCT oil control solenoids. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(ref-344105) .
8. Connect the 2 CMP sensor electrical connectors and attach the wiring harness retainer to the engine front cover stud bolt.
9. Connect the CKP electrical connector.
10. Attach the wiring harness retainer to the engine front cover stud bolt.
11. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
12. Position the generator and install the stud. Tighten to 8 Nm (71 lb-in).
13. Install the generator bolt and 2 nuts. Tighten to 47 Nm (35 lb-ft).
14. Install the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-344117-S37384209342009101600000) and «CRANKSHAFT FRONT SEAL»(ref-344117-S36993205562009101600000) .
15. Fill the engine with clean engine oil.
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
17. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

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. Failure to verify correct timing drive component alignment will result in severe engine damage.

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344117-S21480508332009101600000) .
2. Remove the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .
3. Remove the ignition pulse wheel.
4. Install the crankshaft pulley bolt and washer.
5. 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.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the 2 bolts and the RH timing chain guide. Remove the RH timing chain from the engine.
10. Rotate the crankcase clockwise 600 degrees (one and two-third turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the 2 bolts and the LH timing chain guide. Remove the LH timing chain from the engine.
14. Remove the crankshaft pulley bolt and the crankshaft sprocket.

Scheme 365

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

Scheme 371

1. 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.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
6. 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.
7. 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.
8. 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).
9. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. 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.
12. 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).
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to TDC.
15. 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.
16. Remove the crankshaft pulley bolt and washer.
17. Install the ignition pulse wheel.
18. Install the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-344124) .
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344117-S21480508332009101600000) .

1. Remove the camshaft phaser and sprocket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(ref-344117-S03258028722009101600000) .
2. Remove and discard the VCT system oil filter from the camshaft.

1. Install the new VCT system oil filter in the camshaft.
2. Install the camshaft phaser and sprocket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(ref-344117-S03258028722009101600000) .

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-344117-S32120061392009101600000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

1. Using the Valve Stem Oil Seal Installer, install the valve seal.
2. Using the Valve Spring Compressor, install the valve spring, retainer and key.
3. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-344117-S32120061392009101600000) .

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.

Scheme 372

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-344117-S25711188572009101600000) .
3. Remove the coolant pump housing. For additional information, refer to «ENGINE COOLING»(ref-344113) .
4. Remove the RH camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-344117-S07291262992009101600000) and «CAMSHAFTS - RH»(ref-344117-S40369843642009101600000) .
5. Remove the camshaft roller followers.
6. Remove the hydraulic lash adjusters.
7. Remove the RH exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
8. Remove the bolts in the sequence shown. Remove the cylinder head. Discard the bolts and gasket.
9. Support the cylinder head 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) .

Scheme 373

1. Use a plastic scraping tool to remove all traces of the head gasket. Clean all surfaces with metal surface prep.
2. Position a new gasket and the cylinder head.
3. Install the bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. 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.
4. Install the RH exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
6. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
7. Install the RH camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-344117-S07291262992009101600000) and «CAMSHAFTS - RH»(ref-344117-S40369843642009101600000) .
8. Install the coolant pump housing. For additional information, refer to «ENGINE COOLING»(ref-344113) .
9. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-344117-S25711188572009101600000) .

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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-344117-S25711188572009101600000) .
3. Remove the coolant pump housing. For additional information, refer to «ENGINE COOLING»(ref-344113) .
4. Remove the LH camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-344117-S07291262992009101600000) and «CAMSHAFTS - LH»(ref-344117-S17977494422009101600000) .
5. Remove the camshaft roller followers.
6. Remove the hydraulic lash adjusters.
7. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
8. Remove the 4 upper radiator support bracket bolts.
9. Remove the oil level indicator.
10. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator support and the cooling fan. Remove and discard the O-ring seal.
11. Remove the bolts in the sequence shown.
12. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
13. Support the cylinder head 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) .

Scheme 374

1. Position a new gasket and the cylinder head.
2. Install the bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. 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.
3. Guide the oil level indicator tube between the radiator support and the cooling fan and install it in the orifice, install the stud bolt. To install, tighten to 10 Nm (89 lb-in).
4. Install the oil level indicator.
5. Install the 4 upper radiator support bracket bolts. Tighten to 10 Nm (89 lb-in).
6. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
7. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
8. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
9. Install the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-344117-S07291262992009101600000) and «CAMSHAFTS - LH»(ref-344117-S17977494422009101600000) .
10. Install the coolant pump housing. For additional information, refer to «ENGINE COOLING»(ref-344113) .
11. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-344117-S25711188572009101600000) .

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.

Scheme 375

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
3. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
4. Remove and discard the oil filter.
5. Remove the access cover.
6. Remove the 2 oil pan-to-transaxle bolts.
7. Remove the 15 bolts and the oil pan. Remove and discard the oil pan gasket.

Scheme 376

1. Use a plastic scraping tool to remove all traces of the oil pan gasket. Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
2. Apply a 10 mm (0.40 in) diameter dot of silicone sealant to the areas indicated.
3. Position the oil pan and loosely install the bolts.
4. Install the 2 oil pan-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
5. Tighten the oil pan-to-engine bolts in the sequence shown to 25 Nm (18 lb-ft).
6. Install the access cover.
7. Install a new oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
8. Install the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
9. Fill the engine with clean engine oil.

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.

Scheme 377

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the oil pan. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-344117-S18684743782009101600000) and «OIL PAN»(ref-344117-S21041645522009101600000) .
3. Remove the bolts the oil pump screen and pickup tube. Remove and discard the O-ring seal.

Scheme 378

1. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate the O-ring seal with clean engine oil.
2. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the bolts and tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-344117-S21041645522009101600000) .

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.

Scheme 379

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-344117-S18684743782009101600000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-344117-S11107022072009101600000) .
3. Remove the 8 nuts and the oil pan baffle in the following sequence. To install, 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.
4. To install, reverse the removal procedure.

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.

Scheme 380

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 oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-344117-S18684743782009101600000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-344117-S11107022072009101600000) .
4. Remove the bolts in the sequence shown.

Scheme 381

1. Position the oil pump and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-344117-S18684743782009101600000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-344117-S11107022072009101600000) .
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344117-S11310313912009101600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the engine oil filter. To install, tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 14 Nm (124 lb-in).
5. To install, reverse the removal procedure. Apply thread sealant to the EOP switch threads.

1. Remove the Air Cleaner (ACL) outlet pipe and the ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(ref-344099) .
2. Detach the upper radiator hose from the 2 retaining clips on the cooling fan shroud. Position the hose aside.
3. Remove the 4 upper radiator support bracket bolts. To install, tighten to 10 Nm (89 lb-in).
4. Remove the oil level indicator.
5. Remove the 3 bolts and position aside the heat shield. To install, tighten to 10 Nm (89 lb-in).
6. Detach the wiring harness retainer from the oil level indicator tube.
7. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator support and the cooling fan. Remove and discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
8. To install, reverse the removal procedure.

Scheme 382

PART NUMBER DESCRIPTION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the 3.0L RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
4. Remove the 3 exhaust manifold heat shield bolts and the heat shield.
5. Remove the EGR tube fitting nut from the exhaust manifold.
6. Remove and discard the 6 exhaust manifold nuts.
7. Remove the exhaust manifold and discard the exhaust manifold gasket.
8. Remove and discard the 6 exhaust manifold studs.
9. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .

Scheme 383

1. Install the 6 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 6 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).
3. Install the EGR tube fitting nut on the exhaust manifold. Tighten to 40 Nm (30 lb-ft).
4. Install the exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
5. Connect the HO2S electrical connector.
6. Install the 3.0L RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .

All vehicles

Scheme 384

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
4. Remove the Air Cleaner (ACL) outlet pipe and ACL assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(ref-344099) .
5. Remove the front wheels and tires. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
6. Remove the lower splash shields.
7. Remove the 4 bolts and the lateral support crossmember.
8. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
9. Disconnect the RH CMS electrical connector.
10. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
11. Remove the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
12. Remove the 2 intermediate shaft bearing retainer nuts.
13. Remove the intermediate shaft. All-Wheel Drive (AWD) vehicles
14. Remove and discard the 6 front driveshaft-to-PTU bolts and washers. Position the driveshaft aside and support with mechanic's wire. All vehicles
15. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
16. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-344113) .
17. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
18. Disconnect the A/C compressor electrical connector.
19. Remove the 3 bolts and position the A/C compressor aside.
20. Disconnect the generator electrical connector.
21. Remove the front roll restrictor bolt and the 2 bolts for the engine support cross brace.
22. Remove the rear nut and the engine support crossmember. Discard the nut.
23. Remove the 2 secondary latches from the transaxle fluid cooler tubes.
24. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown).
25. Disconnect the 2 transmission electrical connectors and detach the wiring retainer from the stud bolt.
26. Disconnect the upper and lower radiator hoses.
27. Disconnect the 2 heater hoses.
28. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
29. Disconnect the gearshift cable from the transaxle.
30. Remove the 2 shift cable bracket bolts, and position the cable and bracket aside.
31. Detach the shift cable retainer from the bracket.
32. Disconnect the Evaporative Emission (EVAP) canister purge valve tube and disconnect the brake booster vacuum tube from the intake manifold.
33. Disconnect the middle PCM electrical connector and the engine wiring harness electrical connector. Detach the 2 wiring harness retainers.
34. Detach the wiring harness retainer from the battery tray bracket.
35. Remove the bolt and detach the ground wire.
36. Remove the nut and disconnect the cable from the Power Distribution Box (PDB).
37. Disconnect the electrical connector from the PDB.
38. Remove the nut and the ground wire eyelet from the engine mount stud.
39. If equipped, disconnect the engine block heater electrical connector.
40. Remove the access cover.
41. Remove the 4 torque converter nuts.
42. Remove the 2 oil pan-to-transaxle bolts.
43. Remove the 2 nuts and the transaxle-to-engine stud.
44. Remove the 3 bolts and the halfshaft support bracket.
45. Using the Universal Adapter Brackets, secure the engine and transaxle to the Powertrain Lift.
46. Remove the RH transaxle support insulator bolt.
47. Remove the bolt, nuts and the RH transaxle support insulator.
48. Remove the rear transaxle support through bolt.
49. Remove the 3 engine support bracket nuts and the bolt. Remove the engine support bracket.
50. Lower the powertrain from the vehicle.
51. Remove the nut and the starter wiring ground.
52. Remove the 2 nuts and the starter wiring.
53. Remove the 2 stud bolts and the starter. AWD vehicles
54. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
55. Remove the 3 bolts and the RH heat shield.
56. Remove the 3 nuts and the RH catalytic converter. Discard the nuts and gasket.
57. Remove the bolts and the Power Transfer Unit (PTU) support bracket.
58. Remove the bolt, detach the pin-type retainer and position the PTU vent tube aside.
59. Remove the 3 PTU bolts.
60. Remove the bolt and the PTU.
61. Remove the 3 bolts and the PTU heat shield.
62. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles
63. Install the lower half of the Engine Lifting Bracket Set.
64. Install the upper half of the Engine Lifting Bracket Set.
65. Install the Universal Adapter Brackets and the Engine Lifting Bracket to the front of the RH cylinder head.
66. Install the Universal Adapter Brackets and the Engine Lifting Bracket to the rear of the LH cylinder head.
67. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine and transaxle from the Powertrain Lift.
68. Remove the 5 remaining transaxle-to-engine bolts (3 shown).
69. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, separate the engine and transaxle.

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.

All vehicles

Scheme 440

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Scheme 448

1. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the engine with the transaxle.
2. Install the 5 transaxle-to-engine bolts (3 shown). Tighten to 48 Nm (35 lb-ft).
3. Using the Universal Adapter Brackets, secure the engine and transaxle to the Powertrain Lift. All-Wheel Drive (AWD) vehicles
4. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
5. Install the Power Transfer Unit (PTU) heat shield and the 3 bolts. Tighten to 11 Nm (97 lb-in).
6. Position the PTU and install the bolt. Tighten to 45 Nm (33 lb-ft).
7. Install the 3 PTU bolts. Tighten to 45 Nm (33 lb-ft).
8. Install the PTU vent tube, the pin-type retainer and the bolt. Tighten to 14 Nm (124 lb-in).
9. Install the PTU support bracket and bolts. Tighten to 55 Nm (41 lb-ft).
10. Install a new gasket and the RH catalytic converter and the 3 new nuts. Tighten to 40 Nm (30 lb-ft).
11. Install the 3 bolts and the RH heat shield. Tighten to 10 Nm (89 lb-in).
12. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
13. Install the 2 stud bolts and the starter. Tighten to 27 Nm (20 lb-ft).
14. Install the 2 nuts and the starter wiring. Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in). Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
15. Install the nut and the starter wiring ground. Tighten to 18 Nm (159 lb-in).
16. Position the powertrain into the vehicle.
17. Install the engine support bracket, the bolt and the 3 nuts. Tighten the nuts to 55 Nm (41 lb-ft). Tighten the bolt to 90 Nm (66 lb-ft).
18. Install the rear transaxle support through bolt. Tighten to 103 Nm (76 lb-ft).
19. Position the RH transaxle support insulator and install the bolt and nuts. Tighten to 80 Nm (59 lb-ft).
20. Install the RH transaxle support insulator through bolt. Tighten to 115 Nm (85 lb-ft).
21. Install the 3 bolts and the half shaft support bracket. Tighten to 48 Nm (35 lb-ft).
22. Install the transaxle-to-engine stud and 2 nuts. Tighten to 48 Nm (35 lb-ft).
23. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
24. Position the oil pan and gasket and loosely install the bolts and stud bolts.
25. Install the 2 oil pan-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
26. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
27. Install the 4 torque converter nuts. Tighten to 40 Nm (30 lb-ft).
28. Install the access cover.
29. If equipped, connect the engine block heater electrical connector.
30. Install the ground wire eyelet and nut to the engine mount stud. Tighten to 25 Nm (18 lb-ft).
31. Connect the electrical connector to the Power Distribution Box (PDB).
32. Install the cable and the nut to the PDB. Tighten to 12 Nm (106 lb-in).
33. Attach the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
34. Attach the wiring harness retainer to the battery tray bracket.
35. Connect the middle PCM electrical connector and the engine wiring harness electrical connector. Attach the 2 wiring harness retainers.
36. Connect the Evaporative Emission (EVAP) canister purge valve tube and the brake booster vacuum tube to the intake manifold.
37. Attach the shift cable retainer to the bracket.
38. Position the shift cable and bracket in place, install the bolts. Tighten to 23 Nm (17 lb-ft).
39. Connect the gearshift cable to the transaxle.
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
41. Connect the 2 heater hoses.
42. Connect the upper and lower radiator hoses.
43. Connect the 2 transmission electrical connectors and attach the wiring retainer to the stud bolt.
44. Connect the 2 transaxle fluid cooler tubes.
45. Install the 2 secondary latches to the transaxle fluid cooler tubes.
46. Install the cross brace and the new nut finger-tight.
47. Install the 2 bolts for the cross brace and the bolt for the front roll restrictor. Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
48. Tighten the cross brace nut to 175 Nm (129 lb-ft).
49. Connect the generator electrical connector.
50. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
51. Connect the A/C compressor electrical connector.
52. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. AWD vehicles
53. Align the index-marks made during removal and install 6 new front driveshaft-to-PTU bolts and washers. Tighten to 37 Nm (27 lb-ft). All vehicles
54. Install the intermediate shaft.
55. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 Nm (20 lb-ft).
56. Install the RH and LH halfshaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
57. Install the exhaust-Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
58. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
59. Connect the LH CMS electrical connector.
60. Install the lateral support crossmember and the 4 bolts. Tighten to 115 Nm (85 lb-ft).
61. Install the lower splash shields and bolts. Tighten to 9 Nm (80 lb-in).
62. Install the front wheels and tires. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
63. Install the Air Cleaner (ACL) outlet pipe and ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(ref-344099) .
64. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
65. Fill the engine with clean engine oil.
66. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-344113) .
67. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.