ENGINE-4.6L 2V: Removal & Installation Ford Explorer III

Removal and Installation

Scheme 446

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Scheme 452

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047) .
3. Disconnect the fuel line from the fuel injection supply manifold. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
4. Illustration l of 7. Remove the components in the order indicated in the following illustration and table.
5. Illustration 2 of 7. Remove the components in the order indicated in the following illustration and table.
6. Illustration 3 of 7. Remove the components in the order indicated in the following illustration and table.
7. Illustration 4 of 7. Remove the components in the order indicated in the following illustration and table.
8. Illustration 5 of 7. Remove the components in the order indicated in the following illustration and table.
9. Illustration 6 of 7. Remove the components in the order indicated in the following illustration and table.
10. Illustration 7 of 7. Remove the components in the order indicated in the following illustration and table.
11. To install, reverse the removal procedure.
12. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047) .
13. Connect the fuel line to the fuel injection supply manifold. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
14. Connect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .

Scheme 453

1. Remove the brake booster vacuum tube retaining bolt and disconnect the vacuum tube.

Scheme 454

1. Disconnect the accelerator cable, the speed control cable and the return spring from the throttle body and the bracket, and position the cables aside.

Scheme 455

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Scheme 459

1. Disconnect the fuel rail ground wire.
2. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.
3. Disconnect the differential pressure feedback EGR system electrical connector.
4. Disconnect the eight fuel injector electrical connectors.
5. Separate the wire harness locators and the knock sensor electrical connector from the back of the intake manifold.

Scheme 460

1. Tighten the retaining bolts in the sequence shown in illustration.

Scheme 461

Scheme 462

Scheme 463

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Scheme 465

1. Separate the wire harness locators and the knock sensor electrical connector from the back of the intake manifold.
2. Disconnect the eight fuel injector electrical connectors.
3. Disconnect the differential pressure feedback EGR system electrical connector.
4. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.
5. Disconnect the fuel rail ground wire.

Scheme 466

1. Connect the accelerator cable, the speed control cable and the return spring to the throttle body and the bracket.

Scheme 467

1. Connect the brake booster vacuum tube and install the retaining bolt.

Scheme 468

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Scheme 470

1. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table.
2. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.

Scheme 471

1. Disconnect the positive crankcase ventilation (PCV) tube from the valve cover.

Scheme 472

1. Remove the engine oil level indicator tube retaining bolt, then position the indicator tube aside.

Scheme 473

1. Disconnect the LH engine wiring harness retainers from the valve cover studs.
2. Position the left side of the fuel charging wiring harness away from the valve cover.
3. Loosen the studs.

Scheme 474

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Scheme 476

1. Disconnect the evaporative emissions (EVAP) canister purge solenoid electrical connector.
2. Remove the EVAP canister purge solenoid bracket bolt and position the solenoid aside.
3. Clean and inspect the valve cover mating surface of the cylinder head with metal surface cleaner.
4. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 477

Scheme 478

Scheme 479

Scheme 480

1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover.
2. Apply the silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
3. Tighten the valve cover bolts in the sequence shown in illustration.
4. Connect the LH engine wiring harness retainers to the valve cover studs.
5. Disconnect the evaporative emissions (EVAP) canister purge solenoid electrical connector.
6. Remove the EVAP canister purge solenoid bracket retaining bolt and position the solenoid aside.

Scheme 481

Scheme 482

Scheme 483

1. Remove the air cleaner outlet pipe. For additional information, refer to «REMOVAL & INSTALLATION»(ref-156578) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047) .
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table.
4. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Scheme 484

1. Disconnect the vacuum hose and position the heater control valve assembly aside.

Scheme 485

Scheme 486

1. Disconnect the vacuum hoses from the throttle body adapter and the fuel pressure regulator.
2. Position the vacuum harness away from the valve cover.
3. Disconnect then RH engine wiring harness retainers from the valve cover studs and position the harness aside.
4. Loosen the studs.
5. Clean and inspect the mating surface.

Item 11: RH Valve Cover Removal Note

1. Remove the RH ignition coils. Disconnect the ignition coil connectors. Remove the bolts and ignition coils.
2. Clean and inspect the valve cover mating surface of the cylinder head with metal surface cleaner.
3. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 487

Scheme 488

Scheme 489

Scheme 490

1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover.
2. Apply the silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
3. Tighten the valve cover bolts in the sequence shown in illustration.
4. Connect the RH engine wiring harness retainers to the valve cover studs.
5. Connect the vacuum hoses to the throttle body adapter and the fuel pressure regulator.

Scheme 491

1. Connect the vacuum hose to the heater control valve assembly.

Scheme 492

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Scheme 495

1. Remove the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047).
2. To remove individual components, carry out only the listed steps (Scheme 498)
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Install the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047).

Scheme 496

1. Rotate the tensioner clockwise and remove the drive belt.

Scheme 497

1. Detach the lower radiator hose from the two clips.

Scheme 498

1. Use the special tool to hold the crankshaft pulley and remove the crankshaft pulley bolt.

Scheme 499

1. Use the special tool to remove crankshaft pulley.

Scheme 500

1. Remove the front cover seal with the special tools.

Scheme 501

1. Lubricate the front cover and the crankshaft front seal inner lip with clean engine oil.
2. Install the crankshaft front seal using the special tool.

Scheme 502

1. Install the crankshaft pulley within four minutes of applying silicone gasket and sealant to the Woodruff key slot.
2. Using the special tool, install the crankshaft pulley.

Scheme 503

1. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in four stages: Stage 1: Tighten the bolt to 90 Nm (66 lb-ft). Stage 2: Loosen the bolt one full turn. Stage 3: Tighten the bolt to 50 Nm (37 lb-ft). Stage 4: Tighten the bolt an additional 90 degrees without exceeding 200 Nm (148 lb-ft).

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Scheme 509

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047).
2. Remove the front crankshaft seal. For additional information, refer to «CRANKSHAFT PULLEY AND CRANKSHAFT SEAL»(ref-194045-S11640361932005092600000).
3. Remove the roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-194045-S21226984142005092600000).
4. Drain the engine oil.
5. To remove individual components, carry out only the listed steps (Scheme 511), (Scheme 512) and (Scheme 513).
6. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table.
7. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table.
8. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table.
9. To install. reverse the removal procedure.
10. Fill the engine with clean engine oil.
11. Fill and bleed the engine cooling system. For additional information Refer to «ENGINE COOLING»(ref-194047).
12. Install the roller followers. For additional information. refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-194045-S21226984142005092600000).
13. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-194037).

Scheme 510

Scheme 511

Scheme 512

1. Remove the power steering reservoir bolts.
2. Loosen the clamps, disconnect the hoses and remove the reservoir. Drain the fluid into a suitable container.
3. Using the special tool. remove the power steering pump pulley.
4. Remove the nuts and position the wiring bracket out of the way.

Scheme 513

1. Remove the brackets.

Scheme 514

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Scheme 516

1. Remove the upper radiator hose bracket.
2. Remove the radio capacitors.
3. Remove the power steering reservoir bracket.

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Scheme 519

1. Remove the transmission cooler line bracket from the stud.
2. Remove the engine front cover fasteners in the sequence shown in illustrations.

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Scheme 534

1. Using the special tool, position the crankshaft. Remove the special tool after crankshaft positioning.
2. Install the crankshaft sprocket with the flange facing forward.
3. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the liming mark is at approximately the 11 o'clock position.
4. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
5. If the copper links are not visible. mark one link on one end and one link on the other end, and use as timing marks.
6. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
7. Position the LH timing chain on the camshaft sprocket. Make sure the copper- colored link aligns with the camshaft sprocket timing mark.
8. Compress the LH tensioner plunger, using a vise.
9. Install a retaining clip on the LH tensioner to hold the plunger in during installation.
10. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
11. Remove the retaining clip from the LH timing chain tensioner.
12. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
13. Position the RH timing chain on the camshaft sprocket. Make sure the copper- colored link aligns with the camshaft sprocket timing mark.
14. Compress the RH tensioner plunger, using a vise.
15. Install a retaining clip on the RH tensioner to hold the plunger in during installation.
16. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
17. Remove the retaining clip from the RH timing chain tensioner.
18. As a post-check, verify correct alignment of all timing marks.
19. Install the crankshaft sensor ring on the crankshaft.

Scheme 535

Scheme 536

1. Apply silicone gasket and sealant in the locations shown in illustration.
2. Install the engine front cover.
3. Tighten the four oil pan bolts in the sequence shown in illustration: Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.

Scheme 537

1. Using the appropriate special tool, install a new O-ring seal on the power steering pressure hose fitting.

Scheme 538

1. Using the special tool, install the power steering pump pulley.

Scheme 539

Scheme 540

Scheme 541

1. Remove the engine front cover, timing gears, chain and tensioners. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000).
2. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-194045-S04530018752005092600000) and «VALVE COVER RH»(ref-194045-S28706914482005092600000).
3. To remove individual components, carry out only the listed steps (Scheme 551)
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.
6. Install the engine front cover, timing gears, chain and tensioners. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000).

Items 1-4: Valve Spring Retainer Keys, Valve Spring Retainer, Valve Springs, and Valve Stem Seals Removal Note

Note. Carry out the following steps for each cylinder requiring service.

Scheme 542

1. Use compressed air in the cylinder to hold both valves in position.
2. Using the special tools, compress the valve spring.
3. Remove the valve spring retainer keys, the valve spring retainers, the valve spring and if necessary the valve stem seal.

Scheme 543

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Scheme 547

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft onto the cylinder head.
3. Lubricate the camshaft bearing caps with clean engine oil.
4. Install the camshaft bearing caps and loosely install the bolts.
5. Tighten the bolts in the sequence shown in illustration.

Scheme 548

1. Install the camshaft gear spacer.
2. Install the camshaft sprocket. Tighten the sprocket bolt in two stages. Stage 1: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.

Item 4: Valve Stem Seal Installation Note

1. Using the special tools, install the new valve stem seals.

Scheme 549

Scheme 550

1. Install the special tool between the valve spring coils to protect the valve stem seal from damage.
2. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys.
3. Remove the special tool from the valve spring coils.

Scheme 551

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Scheme 553

Scheme 554

1. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-194045-S04530018752005092600000) and «VALVE COVER RH»(ref-194045-S28706914482005092600000).
2. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047).
3. Remove the spark plugs.
4. To remove individual components, carry out only the listed steps (Scheme 568)
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.
7. Install the spark plugs. Tighten to 18 Nm (13 lb-ft).
8. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047).
9. Install the valve covers. For additional information, refer to «VALVE COVER LH»(ref-194045-S04530018752005092600000) and «VALVE COVER RH»(ref-194045-S28706914482005092600000).

Scheme 555

Scheme 556

Scheme 557

1. Disconnect the electrical connectors, remove the bolts, and the LH and RH ignition coils. Tilt the coils away from the fuel injection supply manifold to remove.
2. Rotate the crankshaft until the cam lobe is directly away from the roller follower.
3. Install the special tool between the valve spring coils to prevent valve stem seal damage.
4. Using the special tool, compress the valve springs and remove the camshaft roller followers.

Scheme 558

Scheme 559

1. Rotate the crankshaft until the cam lobe is directly away from the roller follower.
2. Using the special tool, compress the valve springs and install the camshaft roller followers.
3. Install the LH and RH ignition coils and electrical connectors.

Scheme 560

1. With the vehicle in neutral, position it on a hoist.
2. Remove the RH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Install the RH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .

Scheme 561

1. Tighten the exhaust manifold nuts in the sequence shown in illustration.

Scheme 562

1. With the vehicle in neutral, position it on a hoist.
2. Remove the LH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Install the LH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .

Item 1: Steering Gear Shaft Removal Note

1. Remove the lower steering column shaft pinch bolt. Position the lower steering column shaft aside.

Scheme 563

1. Tighten the exhaust manifold nuts in the sequence shown in illustration.

Scheme 564

Scheme 565

Scheme 566

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-194045-S09764723422005092600000) .
2. Slide the water heater tube back and remove. Discard the O-ring seal.
3. Remove the timing chains. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000) .
4. Remove the exhaust manifolds. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-194045-S22887417642005092600000) and «EXHAUST MANIFOLD - RH»(ref-194045-S31038972062005092600000) .
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.
7. Install the exhaust manifolds. For additional information, refer to «EXHAUST MANIFOLD-RH»(ref-194045-S31038972062005092600000) and «EXHAUST MANIFOLD-LH»(ref-194045-S22887417642005092600000) .
8. Install the timing chains. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000) .
9. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-194045-S09764723422005092600000) .

Scheme 567

1. Remove the bolts and the RH cylinder head. Discard the head gasket and clean the engine block surface with a plastic scraper and metal surface cleaner.

Items 4-6: LH Cylinder Head, Bolts and Gaskets Removal Note

1. Remove the bolts and the LH cylinder head. Discard the head gasket and clean the cylinder block surface with a plastic scraper and metal surface cleaner.

Items 1-6: RH and LH Cylinder Head, Bolts and Gaskets Installation Note

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the head gasket and loosely install the bolts.
3. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Back out all bolts one full turn (360 degrees). Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.
4. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Back out all bolts one full turn (360 degrees). Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.

Scheme 568

Scheme 569

1. With the vehicle in neutral, position it on a hoist.
2. Drain the coolant. For additional information, refer to «ENGINE COOLING»(ref-194047) .
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047) .

Scheme 570

Scheme 571

1. With the vehicle in neutral, position it on a hoist.
2. Remove the LH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .
3. To install, reverse the removal procedure.
4. Install the LH inner fender well. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068) .

Scheme 572

1. Tighten the exhaust manifold nuts in the sequence shown in illustration.

Scheme 573

Scheme 574

Scheme 575

1. Remove the front axle, if equipped. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029).
2. Remove the stabilizer bar, if equipped. For additional information, refer to «SUSPENSION SYSTEM»(ref-194026).
3. Drain the engine oil.
4. If the oil pump is to be removed, remove the timing chains. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000).
5. Remove the components in the order indicated in (Scheme 597).
6. To install, reverse the removal procedure.
7. Install the front axle, if equipped. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029).
8. Install the stabilizer bar, if equipped. For additional information, refer to «SUSPENSION SYSTEM»(ref-194026).
9. Fill the engine with clean engine oil.
10. If the oil pump was removed, install the timing chains. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-194045-S20769476292005092600000).

Scheme 576

Scheme 577

1. Remove and discard the oil pan gasket. Clean the sealing surfaces with metal surface cleaner. Allow the surfaces to dry for four minutes or until there is no sign of wetness, whichever is longer. Failure to do so can cause future oil leaks.
2. Apply silicone gasket and sealant in two places.
3. Apply silicone gasket and sealant in two places.
4. Position the new oil pan gasket and the oil pan and loosely install the bolts.
5. Tighten the bolts in three stages in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
6. Fill the engine with clean engine oil.

Scheme 578

Scheme 579

Scheme 580

Scheme 581

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049).
2. Remove the oil pan. For additional information, refer to «OIL PAN, OIL PUMP, OIL PUMP SCREEN AND PICKUP TUBE»(ref-194045-S28546243152005092600000).
3. Remove the components in the order indicated in (Scheme 605).
4. To remove individual components, carry out only the listed steps (Scheme 605)
5. To install, reverse the removal procedure.
6. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049).
7. Install the oil pan. For additional information, refer to «OIL PAN, OIL PUMP, OIL PUMP SCREEN AND PICKUP TUBE»(ref-194045-S28546243152005092600000).

Scheme 582

1. Using the special tools, remove the crankshaft rear oil seal slinger.

Scheme 583

1. Using the special tools, remove the crankshaft rear oil seal.

Item 7: Crankshaft Rear Oil Seal Retainer Plate Installation Note

1. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface.

Scheme 584

1. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).

Scheme 585

1. Using the special tools, install the crankshaft rear oil seal. Lubricate the crankshaft rear oil seal with engine oil before installation.

Scheme 586

1. Using the special tools, install the crankshaft rear oil slinger.

Scheme 587

1. Position the flexplate and install the bolts loosely. Tighten the bolts in the sequence shown in illustration.

Scheme 588

Scheme 589

Scheme 590

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-194047).
3. Remove the alternator. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056).
4. Remove the wiper cowling. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068).
5. Remove the exhaust gas recirculation (EGR) system module and the tube assembly. For additional information, refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE»(ref-194045-S08786559832005092600000).
6. Remove the components in the order indicated in (Scheme 615). To remove individual components, carry out only the following steps (Scheme 615)
7. To install, reverse the removal procedure.
8. Install the exhaust gas recirculation (EGR) system module and the tube assembly. For additional information, refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE»(ref-194045-S08786559832005092600000).
9. Install the wiper cowling. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-194068).
10. Install the alternator. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056).
11. Install the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-194047).

Item 1: Stabilizer Bar Bracket Bolts Removal Note

1. Reposition the stabilizer bar to gain clearance.

Item 2: Front Axle Bolts Removal Note

1. Support the axle using an appropriate jack. Lower the axle approximately 150 mm (6 in).

Scheme 591

1. Install the special tools.
2. Raise the engine until the insulator can be removed.

Scheme 592

1. Install the special tools.
2. Raise the engine until the insulator can be removed.

Item 2: Front Axle Bolts Installation Note

1. Raise the front axle into position and loosely install the bolts. Remove the jack.

Scheme 593

Scheme 594

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Scheme 596

Scheme 597

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. Remove the hood.
3. Discharge and recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-194054) .
4. Remove the air cleaner assembly. For additional information, refer to «REMOVAL & INSTALLATION»(ref-156578) .
5. Remove the evaporative emissions canister purge valve. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
6. Remove the cooling fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-194047) .
7. Disconnect the fuel hose spring coupling. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
8. Remove the starter motor. For additional information, refer to «STARTERS»(ref-168028) .
9. Drain the engine oil.
10. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table.
11. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table.
12. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table.

Scheme 598

Scheme 599

Scheme 600

1. Disconnect the fuel charging wiring harness pushpins.
2. Unclip the engine wiring harness retainers, remove the transmission wiring harness from the clips and position the engine wiring harness onto the engine.
3. Remove the heater control valve bracket bolt.
4. Disconnect the heater control vacuum supply hose.

Scheme 601

1. Disconnect the throttle cable assembly and the speed control cable from the throttle cam and position the cables out of the way.

Scheme 602

Scheme 603

Scheme 604

Scheme 605

1. Install the special tools.
2. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049) .
3. Disconnect the LH HO2S wiring harness from the retainer.
4. Using the special tool, disconnect the cooler tubes from the cooler. Drain the fluid into a suitable container.
5. Remove the nut and the cooler tubes.

Scheme 606

Scheme 607

1. Remove special tools 303-290A-03A, 303-290A-01, and 303-290A. Leave special tool 303-D074 attached to engine.
2. Install the special tool.
3. Support fuel hose with a wire tie or mechanic's wire before removing the engine.
4. Remove the engine.

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Scheme 628

1. Illustration 1 of 19. Remove the components in the order indicated in the following illustration and table.
2. Mount the engine on a suitable engine stand.
3. Illustration 2 of 19. Remove the components in the order indicated in the following illustration and table.
4. Illustration 3 of 19. Remove the components in the order indicated in the following illustration and table.
5. Illustration 4 of 19. Remove the components in the order indicated in the following illustration and table.
6. Illustration 5 of 19. Remove the components in the order indicated in the following illustration and table.
7. Illustration 6 of 19. Remove the components in the order indicated in the following illustration and table.
8. Illustration 7 of 19. Remove the components in the order indicated in the following illustration and table.
9. Illustration 8 of 19. Remove the components in the order indicated in the following illustration and table.
10. Illustration 9 of 19. Remove the components in the order indicated in the following illustration and table.
11. Illustration 10 of 19. Remove the components in the order indicated in the following illustration and table.
12. Illustration 11 of 19. Remove the components in the order indicated in the following illustration and table.
13. Illustration 12 of 19. Remove the components in the order indicated in the following illustration and table.
14. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
15. Illustration 13 of 19. Remove the components in the order indicated in the following illustration and table.
16. Illustration 14 of 19. Remove the components in the order indicated in the following illustration and table.
17. Illustration 15 of 19. Remove the components in the order indicated in the following illustration and table.
18. Illustration 16 of 19. Remove the components in the order indicated in the following illustration and table.
19. Illustration 17 of 19. Remove the components in the order indicated in the following illustration and table.
20. Illustration 18 of 19. Remove the components in the order indicated in the following illustration and table.
21. Illustration 19 of 19. Remove the components in the order indicated in the following illustration and table.

Scheme 629

1. Using the special tools, remove the crankshaft oil slinger.

Scheme 630

1. Using the special tools, remove the crankshaft rear seal.