Engine - 4.0L (SOHC): Removal & Installation Ford Explorer IV

REMOVAL AND INSTALLATION

1. Remove the air cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
2. Detach the knock sensor (KS) electrical connector from the intake manifold.
3. Disconnect the PCV tube from the intake manifold.
4. Disconnect the brake booster vacuum hose from the intake manifold.
5. Disconnect the main vacuum harness fitting from the intake manifold.
6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
7. Disconnect the EGR system module electrical connector.
8. Detach the wiring harness retainer.
9. Disconnect the EGR system module vacuum fitting.
10. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. To install, tighten to 34 Nm (25 lb-ft).
11. Disconnect the throttle position (TP) sensor electrical connector.
12. Disconnect the electronic throttle body (TB) electrical connector.
13. Remove the nut and detach the wiring harness bracket from the electronic TB. To install, tighten to 9 Nm (80 lb-in).
14. Remove the bolts, the intake manifold and the gaskets. To install, tighten to 11 N.m (8 lb-ft).
15. Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.
16. To install, reverse the removal procedure.

1. Disconnect the spring lock coupling from the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-270952) .
2. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-270889-S01623241992007110700000) .
3. Remove the heater hose tube bracket rear bolt. To install, tighten to 23 Nm (17 lb-ft).
4. Remove the heater hose tube bracket front bolt. To install, tighten to 34 Nm (25 lb-ft).
5. Loosen the exhaust manifold-to-EGR system module tube lower fitting and remove the tube. To install, tighten to 34 Nm (25 lb-ft).
6. Remove the fuel supply tube-to-valve cover bracket bolt, the fuel supply tube bolts and the fuel supply tube. Remove and discard the O-ring seals. Install new O-ring seals and lubricate them with clean engine oil. To install, tighten to 6 Nm (53 lb-in).
7. Detach the spark plug wire retainers and position the spark plug wires aside.
8. Remove the crankcase ventilation tube.
9. Remove the bolts and the valve cover. To install, tighten to 10 Nm (89 lb-in).
10. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary.
11. To install, reverse the removal procedure.

Scheme 2

Scheme 3

1. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-270889-S01623241992007110700000) .
2. Disconnect the camshaft position (CMP) sensor electrical connector.
3. Disconnect the ignition coil electrical connector. Detach the wiring harness retainer.
4. Disconnect the fuel injector electrical connectors. Detach the wiring harness retainers.
5. Remove the PCV valve tube.
6. Disconnect the PCV valve electrical connector.
7. Detach the spark plug wire retainers.
8. Remove the bolts and the valve cover. To install, tighten to 10 Nm (89 lb-in).
9. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary.
10. To install, reverse the removal procedure.

REMOVAL

1. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-270889-S12256192192007110700000) .
2. Using the special tool, remove and discard the crankshaft front seal.

INSTALLATION

1. Using the special tools, install a new crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-270889-S12256192192007110700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-270902) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-270912) .
4. Using the special tool to hold the crankshaft pulley, remove the bolt.
5. Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley. Discard the crankshaft pulley bolt.

1. Using the special tool, install the crankshaft pulley.
2. Using the special tool to hold the crankshaft pulley, install a new crankshaft pulley bolt. Tighten the bolt in 2 stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten an additional 85 degrees.
3. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-270912) .
4. Install the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-270902) .

Both sides

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .
3. Remove the roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
4. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
5. Remove the bolts and position the heater hose tube bracket aside.
6. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
7. Disconnect the generator electrical connections.
8. Remove the bolt and the accessory drive belt tensioner.
9. Remove the generator mounting bracket assembly.
10. Disconnect the heater hose from the thermostat housing.
11. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
12. Disconnect the upper radiator hose from the thermostat housing.
13. Position the bypass hose clamp aside.
14. Remove the bolts and the thermostat housing.
15. Remove the bolt and position the engine wiring harness aside.
16. Remove the engine ground strap.
17. With a twisting motion, use the special tool to pull the spark plug wires from the RH spark plugs.
18. Remove the RH exhaust manifold. For additional information, refer to «Exhaust Manifold - RH»(ref-270889-S01678143462007110700000) .
19. Remove the RH hydraulic timing chain tensioner.
20. Install the special tools. Tighten to 10 Nm (89 lb-in).
21. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.
22. Remove the RH side cassette-to-cylinder head bolt.
23. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
24. Disconnect the radio ignition interference capacitor electrical connector.
25. Remove the ignition coil and bracket assembly-to-A/C compressor and power steering pump bracket bolts.
26. Remove the bolts and position the A/C compressor and power steering pump bracket aside.
27. Remove the ignition coil and bracket assembly-to-cylinder head bolts and the ignition coil and bracket assembly.
28. Remove the bolt and the oil level indicator tube.
29. Remove the LH exhaust manifold. For additional information, refer to «Exhaust Manifold - LH»(ref-270889-S05561450992007110700000) .
30. Remove the LH hydraulic timing chain tensioner.
31. Install the special tools. Tighten the top clamp bolts to 10 Nm (89 lb-in).
32. Remove the LH side camshaft sprocket bolt.
33. Remove the LH timing cassette-to-cylinder head bolt.
34. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
35. Remove the cylinder heads. Remove the cylinder head bolts in the sequence shown. Discard all bolts. Remove and discard the head gasket.
36. Clean and inspect the mating surfaces.
37. Inspect the cylinder head and the cylinder block for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .

Both sides

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position the cylinder head gasket on the block.
3. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages. Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten to 25 Nm (18 lb-ft).
4. Install 2 new 8-mm bolts. Tighten to 32 Nm (24 lb-ft).
5. Tighten the eight 12-mm bolts in the sequence shown in 2 stages. Stage 1: Tighten 90 degrees. Stage 2: Tighten an additional 90 degrees.
6. Remove the rubber band. Install the camshaft sprocket and bolt.
7. Install the RH timing cassette-to-cylinder head bolt. Tighten to 10 Nm (89 lb-in).
8. Install the RH exhaust manifold. For additional information, refer to «Exhaust Manifold - RH»(ref-270889-S01678143462007110700000) .
9. Connect the spark plug wires to the RH spark plugs.
10. Install the engine ground strap and the bolt. Tighten to 10 Nm (89 lb-in).
11. Position the engine wiring harness and install the bolt. Tighten to 47 Nm (35 lb-ft).
12. Install the thermostat housing and the bolts. Tighten to 11 Nm (8 lb-ft).
13. Position the coolant bypass hose clamp.
14. Install the upper radiator hose to the thermostat housing.
15. Connect the engine coolant temperature (ECT) sensor electrical connector.
16. Connect the heater hose to the thermostat housing.
17. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages. Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten to 25 Nm (18 lb-ft).
18. Install 2 new 8-mm bolts. Tighten to 32 Nm (24 lb-ft).
19. Tighten the eight 12-mm bolts in the sequence shown in 2 stages. Stage 1: Tighten 90 degrees. Stage 2: Tighten an additional 90 degrees.
20. Remove the rubber band. Install the camshaft sprocket and bolt.
21. Install the LH timing cassette-to-cylinder head bolt. Tighten to 12 Nm (9 lb-ft).
22. Install the LH exhaust manifold. For additional information, refer to «Exhaust Manifold - LH»(ref-270889-S05561450992007110700000) .
23. Connect the spark plug wires to the LH spark plugs.
24. Install the oil level indicator tube and the bolt. Tighten to 10 Nm (89 lb-in).
25. Time the camshafts. For additional information, refer to «Camshaft Timing»(ref-270889-S00866897262007110700000) .
26. Install the generator mounting bracket assembly and the bolts. Tighten to 42 Nm (31 lb-ft).
27. Position the accessory drive belt tensioner and install the bolt. Tighten to 47 Nm (35 lb-ft).
28. Connect the generator electrical connections. Tighten to 8 Nm (71 lb-in).
29. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
30. Position the heater hose tube bracket and install the bolts. Tighten the rear bolt to 23 Nm (17 lb-ft). Tighten the front bolt to 34 Nm (25 lb-ft).
31. Position the ignition coil and bracket assembly and install the bracket-to-cylinder head bolts. Tighten to 10 Nm (89 lb-in).
32. Position the A/C compressor and power steering pump bracket and install the bolts. Tighten to 42 Nm (31 lb-ft).
33. Install the ignition coil bracket-to-A/C compressor and power steering pump bracket bolts. Tighten to 10 Nm (89 lb-in).
34. Connect the radio ignition interference capacitor electrical connector.
35. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
36. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .
3. Remove the crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(ref-270889-S20779928822007110700000) .
4. Remove the nut and detach the wiring harness bracket from the front cover.
5. Remove the 5 oil pan-to-front cover bolts.
6. Disconnect the lower radiator hose.
7. Remove the bolt and the drive belt tensioner.
8. Disconnect the heater hose from the coolant pump.
9. Disconnect the crankshaft position (CKP) sensor electrical connector.
10. Disconnect the generator electrical connectors and the wiring harness retainer.
11. Remove the 3 generator bracket bolts and the generator bracket.
12. Remove the coil bracket-to-LH accessory drive bracket bolt.
13. Remove the 4 bolts and the LH accessory drive bracket.
14. Remove and discard the CKP sensor wiring harness retainers.
15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
16. Disconnect the upper radiator hose from the thermostat housing.
17. Disconnect the heater hose from the thermostat housing.
18. Release the bypass hose clamp from the coolant pump end.
19. Remove the 3 bolts and the thermostat housing.
20. Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket.

1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
2. Position the front cover gasket.
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
4. Apply silicone gasket and sealant to the front cover in 2 places.
5. Position the engine front cover and install the 10 bolts. Tighten to 19 Nm (14 lb-ft).
6. Position the thermostat housing and install the 3 bolts. Tighten to 11 Nm (8 lb-ft).
7. Position the bypass hose clamp.
8. Connect the upper radiator hose to the thermostat housing.
9. Connect the heater hose to the thermostat housing.
10. Connect the ECT sensor electrical connector.
11. Install new wiring harness retainers and position the CKP sensor wiring.
12. Connect the CKP sensor electrical connector.
13. Position the LH accessory drive bracket and install the 4 bolts. Tighten to 42 Nm (31 lb-ft).
14. Install the ignition coil bracket-to-LH accessory drive bracket bolt. Tighten to 10 Nm (89 lb-in).
15. Position the generator bracket and install the 3 bolts. Tighten to 42 Nm (31 lb-ft).
16. Connect the generator electrical connectors and the wiring harness retainer. Tighten to 9 Nm (80 lb-in).
17. Connect the heater hose to the coolant pump.
18. Position the accessory drive belt tensioner and install the bolt. Tighten to 47 Nm (35 lb-ft).
19. Connect the lower radiator hose.
20. Install the 5 cylinder block cradle-to-front cover bolts. Tighten to 14 Nm (10 lb-ft).
21. Position the wiring harness bracket and install the nut. Tighten to 20 Nm (15 lb-ft).
22. Install the crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(ref-270889-S20779928822007110700000) .
23. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
24. Fill the engine cooling system For additional information, refer to «ENGINE COOLING»(ref-270902) .

1. Remove the valve covers. For additional information, refer to «Valve Cover - RH»(ref-270889-S17371311932007110700000) and «Valve Cover - LH»(ref-270889-S10705818022007110700000) .
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.0L SOHC»(ref-270904) .
3. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-270889-S35104334932007110700000) .
4. Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-270902) .
5. Remove all of the roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
6. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
7. Remove the LH hydraulic chain tensioner.
8. Remove the LH camshaft sprocket bolt. Install the special tools and tighten the bolts to 10 Nm (89 lb-in). Remove the LH camshaft sprocket bolt.
9. Using the special tool to prevent the crankshaft from turning, remove the jackshaft sprocket bolt.
10. Remove the bolts and the primary chain tensioner.
11. Remove the primary chain and sprockets as an assembly.
12. Remove the LH cassette upper bolt.
13. Remove the LH cassette lower bolt and the LH cassette.

1. Position the LH cassette.
2. Install the LH cassette lower bolt. Tighten to 19 N.m (14 lb-ft).
3. Install the LH cassette upper bolt. Tighten to 12 N.m (9 lb-ft).
4. Install the jackshaft chain and sprockets as an assembly.
5. Install the jackshaft chain tensioner and the bolts. Tighten to 9 N.m (80 lb-in).
6. Using the special tool to prevent the crankshaft from turning, tighten the jackshaft sprocket bolt in 2 stages. Stage 1: Tighten to 45 N.m (33 lb-ft). Stage 2: Tighten an additional 90 degrees.
7. Loosely install the camshaft sprocket bolt.
8. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-270889-S35104334932007110700000) .
9. Re-time the LH and RH camshafts. For additional information, refer to «Camshaft Timing»(ref-270889-S00866897262007110700000) .
10. Install the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
11. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.0L SOHC»(ref-270904) .
12. Install the valve covers. For additional information, refer to «Valve Cover - RH»(ref-270889-S17371311932007110700000) and «Valve Cover - LH»(ref-270889-S10705818022007110700000) .
13. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .

1. Remove the hydraulic chain tensioner. To install, tighten to 44 Nm (32 lb-ft).
2. Remove and discard the O-ring seal.
3. To install, reverse the removal procedure.

1. Remove the hydraulic chain tensioner. To install, tighten to 44 Nm (32 lb-ft).
2. Remove and discard the O-ring seal.
3. To install, reverse the removal procedure.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. For additional information, refer to the appropriate procedures.

Both sides

1. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
2. Remove the nut and position the wiring harness bracket aside.
3. Rotate the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC).
4. Install the special tool.
5. Remove the RH hydraulic timing chain tensioner.
6. Install the special tools on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in).
7. Using the special tool and the Camshaft Sprocket Nut Socket 303-565, loosen the camshaft sprocket bolt.
8. Remove the bolt and position the camshaft sprocket aside.
9. Remove the LH hydraulic timing chain tensioner.
10. Rotate the accessory drive belt tensioner counterclockwise and detach the accessory drive belt from the A/C compressor and power steering pump pulleys.
11. Remove the bolts and position the A/C compressor and power steering pump bracket aside.
12. Install the special tools on the front of the LH camshaft and tighten the 2 top clamp bolts to 10 Nm (89 lb-in).
13. Remove the bolt and position the camshaft sprocket aside.
14. Remove the bolts in the sequence shown and remove the camshaft bearing caps.
15. Remove the camshaft.

Note. Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals and the camshaft bearing caps with clean engine oil.

Both sides

1. Install the camshaft.
2. Position the camshaft bearing caps and the bolts. Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten to 16 Nm (12 lb-ft).
3. Install the camshaft sprocket and loosely install the bolt.
4. Install the camshaft sprocket and loosely install the bolt.
5. Time the camshafts. For additional information, refer to «Camshaft Timing»(ref-270889-S00866897262007110700000) .

1. Remove the LH and RH valve covers. For additional information, refer to «Valve Cover - RH»(ref-270889-S17371311932007110700000) and «Valve Cover - LH»(ref-270889-S10705818022007110700000) .
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.0L SOHC»(ref-270904) .
3. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-270902) .
4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
5. Using the special tool, remove the camshaft roller followers.
6. To install, reverse the removal procedure.

1. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
2. Position the piston of the cylinder being serviced at top dead center (TDC).
3. Hold the valves in the cylinder head. Remove the spark plug of the cylinder being serviced. Use a suitable tool to apply air pressure to the cylinder.
4. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the valve springs.
5. To install, reverse the removal procedure.

1. Remove the valve springs. For additional information, refer to «Valve Springs»(ref-270889-S09118957802007110700000) .
2. Remove the valve seals.

1. Using the special tool, install the valve seal.
2. Install the valve springs. For additional information, refer to «Valve Springs»(ref-270889-S09118957802007110700000) .

1. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure.

Scheme 8

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside.
3. Remove the 6 nuts, the LH exhaust manifold and the gasket. Discard the nuts and the gasket.
4. Remove and discard the 6 LH exhaust manifold studs.

1. Inspect the LH exhaust manifold gasket surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
2. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position a new gasket, the LH exhaust manifold and install 6 new nuts. Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).

Scheme 9

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-270950) .
3. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside.
4. Remove the 6 nuts, the RH exhaust manifold and the gasket. Discard the nuts and the gasket.
5. Remove and discard the 6 RH exhaust manifold studs.

1. Inspect the RH exhaust manifold gasket surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
2. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position a new gasket, the RH exhaust manifold and install 6 new nuts. Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
5. Install the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-270950) .

Scheme 10

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the drain plug and drain the engine oil. To install, tighten to 26 Nm (19 lb-ft).
3. Remove the bolts, the oil pan and the gasket. Discard the gasket. To install, tighten to 11 Nm (8 lb-ft).
4. Clean and inspect the sealing surfaces.
5. To install, reverse the removal procedure.
6. Fill the engine with clean engine oil.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
3. Remove the air cleaner (ACL) outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
4. Remove the starter. For additional information, refer to «STARTING SYSTEM»(ref-270900) .
5. Remove the oil pump screen and pickup tube. For additional information, refer to «Oil Pump Screen and Pickup Tube»(ref-270889-S16556046872007110700000) .
6. Remove the weatherstrip.
7. Remove the bolt and position the power steering fluid reservoir aside.
8. Disconnect the coolant overflow hose. Remove the bolts and the coolant expansion tank.
9. Remove the bolts, unclip the clips and remove the upper fan shroud.
10. Remove the heater tube bracket front bolt.
11. Install the special tool using the previously removed bolt. Tighten to 23 Nm (17 lb-ft).
12. Install the special tools.
13. Remove the bolts and the stabilizer bar brackets.
14. Remove the bolts and the crossmember.
15. Remove the RH engine support insulator nut.
16. Remove the LH engine support insulator through bolt.
17. Remove the 2 transmission-to-cylinder block cradle bolts.
18. Remove the cylinder block cradle rear bolts.
19. Remove the 20 bolts and 2 nuts along the outside of the cylinder block cradle.
20. Remove the 8 cylinder block cradle inner bolts and the 2 washer seals. Discard the washer seals.
21. Raise the engine.
22. Support the front axle with a suitable jack.
23. Disconnect the vent hose from the differential housing vent tube.
24. Remove and discard the axle housing bolts and flag nuts. Lower the axle.
25. Remove the cylinder block cradle.

All vehicles

1. Back the set screws off until they are below the cylinder block cradle boss.
2. Clean the gasket mating surfaces, making sure all the sealant is removed from the cavities on the rear main bearing cap. To clean the sealing area, use a plastic scraping tool, silicone gasket remover and metal surface prep. Follow the directions on the packaging.
3. Apply silicone in the 6 places shown.
4. Position a new gasket and the cylinder block cradle. Install the outer 20 bolts and 2 nuts finger-tight.
5. Install the 2 cylinder block cradle rear Torx bolts finger-tight.
6. Install the 2 transmission-to-cylinder block cradle bolts. Tighten to 47 Nm (35 lb-ft).
7. Tighten the outer 20 bolts and 2 nuts. Tighten the nuts to 10 Nm (89 lb-in). Tighten the bolts to 14 Nm (10 lb-ft).
8. Tighten the 2 cylinder block cradle rear Torx bolts. Tighten to 8 Nm (71 lb-in).
9. Tighten the 8 inserts. Tighten to 3 Nm (27 lb-in).
10. Install the 2 silver-colored bolts and new washer seals finger-tight.
11. Install the 6 remaining inner bolts finger-tight.
12. Tighten the 8 inner bolts in the sequence shown in 2 stages. Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 34 Nm (25 lb-ft).
13. Raise the axle into position and install new bolts and nuts. Tighten to 66 Nm (49 lb-ft).
14. Connect the vent hose to the differential housing vent tube.
15. Lower the engine and remove the special tools.
16. Install the LH engine support insulator through bolt and nut. Tighten to 103 Nm (76 lb-ft).
17. Install the RH engine support insulator nut. Tighten to 90 Nm (66 lb-ft).
18. Position the crossmember and install the bolts. Tighten to 103 Nm (76 lb-ft).
19. Position the stabilizer bar brackets and install the bolts. Tighten to 55 Nm (41 lb-ft).
20. Install the oil pump screen and pickup tube. For additional information, refer to «Oil Pump Screen and Pickup Tube»(ref-270889-S16556046872007110700000) .
21. Install the starter. For additional information, refer to «STARTING SYSTEM»(ref-270900) .
22. Remove the special tool.
23. Install the heater tube bracket front bolt. Tighten to 34 Nm (25 lb-ft).
24. Position the upper fan shroud and install the bolts. Tighten to 7 Nm (62 lb-in).
25. Position the coolant expansion tank, install the bolts and connect the coolant overflow hose. Tighten to 7 Nm (62 lb-in).
26. Position the power steering fluid reservoir and install the bolt. Tighten to 7 Nm (62 lb-in).
27. Install the weatherstrip.
28. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
29. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .

1. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-270889-S04592840942007110700000) .
2. Remove the bolt and the oil pump screen and pickup tube. To install, tighten to 10 N.m (89 lb-in).
3. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .
3. Remove and discard the oil filter. To install, tighten to 13 Nm (10 lb-ft).
4. Disconnect the oil cooler inlet hose from the oil cooler.
5. Disconnect the heater hose from the oil cooler.
6. Loosen the threaded insert and remove the oil cooler. To install, tighten to 57 Nm (42 lb-ft).
7. To install, reverse the removal procedure. Install a new oil filter. Check the engine oil and fill as necessary.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the RH exhaust manifold. For additional information, refer to «Exhaust Manifold - RH»(ref-270889-S01678143462007110700000) .
3. Remove and discard the oil filter. To install, tighten to 13 Nm (10 lb-ft).
4. Loosen the oil cooler threaded insert and position the oil cooler aside. To install, tighten to 57 Nm (42 lb-ft).
5. Remove the bolt and the oil filter adapter. To install, tighten to 57 Nm (42 lb-ft).
6. To install, reverse the removal procedure. Install a new oil filter. Check the engine oil and fill as necessary.

Scheme 11

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S»(ref-270891) .
2. Remove the bolts and the flexplate.

1. Install the flexplate. Tighten the bolts in 3 stages in the sequence shown. Stage 1: Tighten to 13 Nm (10 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees.
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S»(ref-270891) .

1. Remove the flexplate. For additional information, refer to «Flexplate»(ref-270889-S11514976932007110700000) .
2. Remove the spacer plate.
3. Remove the flexplate-to-crankshaft spacer.
4. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
5. Using the special tool, remove the crankshaft rear seal.

1. Lubricate the crankshaft rear oil seal with clean engine oil.
2. Install the special tools.
3. Position the crankshaft rear seal.
4. Using the special tool, install the crankshaft rear seal.
5. Install the flexplate-to-crankshaft spacer.
6. Install the spacer plate.
7. Install the flexplate. For additional information, refer to «Flexplate»(ref-270889-S11514976932007110700000) .

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
3. Remove the weatherstrip.
4. Remove the bolt and position the power steering fluid reservoir aside. To install, tighten to 7 Nm (62 lb-in).
5. Disconnect the coolant overflow hose. Remove the bolts and the coolant expansion tank. To install, tighten to 7 Nm (62 lb-in).
6. Remove the bolts, unclip the clips and remove the upper fan shroud. To install, tighten to 7 Nm (62 lb-in).
7. Remove the bolt and install the lifting eye.
8. Install the special tools.
9. Remove the LH engine support insulator through bolt. To install, tighten to 103 Nm (76 lb-ft).
10. Remove the pushpins and the RH inner fender splash shield.
11. Remove the RH engine support insulator nuts. To install, tighten to 90 Nm (66 lb-ft).
12. Raise the engine approximately 60 mm (2.36 in).
13. Remove the RH engine support insulator.
14. Remove the bolts and the stabilizer bar brackets. Allow the stabilizer bar to hang freely. To install, tighten to 55 Nm (41 lb-ft).
15. Support the axle with a suitable jack.
16. Disconnect the differential housing vent hose from the differential housing vent tube.
17. Remove and discard the differential housing bolts and flag nuts. Lower the differential housing approximately 25 mm (1 in). To install, tighten to 66 Nm (49 lb-ft).
18. Remove the nut and the LH engine support insulator. To install, tighten to 90 Nm (66 lb-ft).
19. To install, reverse the removal procedure.

Special Tools Illustration Tool Name Tool Number Lifting Brackets 303-050 (T70P-6000) or equivalent Spreader Bar 303-D701 or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-270952) .
3. Disconnect the battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
4. Remove the nut and disconnect the ground wire.
5. Disconnect the electrical connector and detach the wiring harness retainers.
6. Lift the cover, remove the nuts and disconnect the battery cable connector. Lay the wiring harness on top of the engine.
7. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-270953) .
8. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .
9. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-270902) .
10. Remove the air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
11. Disconnect the windshield washer hose.
12. Remove the 4 bolts and the hood.
13. Disconnect the wiring harness electrical connector and the engine wiring harness-to-PCM electrical connectors. Detach the wiring harness retainer.
14. Disconnect the heater hoses and the vacuum hose. Disconnect the heater control valve vacuum hose.
15. Remove the bolt and position the ground wire aside.
16. Disconnect the evaporative emissions (EVAP) hose.
17. Remove the upper radiator hose.
18. Loosen the power steering pump pulley bolts.
19. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
20. Remove the bolts and the power steering pump pulley.
21. Disconnect the lower radiator hose from the coolant pump.
22. Disconnect the power steering pressure (PSP) switch electrical connector.
23. Remove the PSP hose and the power steering reservoir-to-power steering pump supply hose bracket bolts.
24. Remove the bolts and position the power steering pump aside.
25. Disconnect the brake booster vacuum hose.
26. Disconnect the EVAP canister purge valve electrical connector. Disconnect and remove the EVAP hose.
27. Remove the nuts and detach the A/C tubes.
28. Disconnect the A/C high pressure switch, remove the nut, open the retaining clip and remove the A/C tube.
29. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S»(ref-270891) .
30. Remove the terminal cover. Remove the nuts, detach the wires and remove the starter.
31. Remove the oil filter.
32. Remove the nut and detach the transmission cool tube bracket. Support the transmission cooler tubes with mechanic's wire.
33. Remove the nut and detach the battery cable harness bracket from the frame rail.
34. Remove the LH engine support insulator through bolt.
35. Remove the RH engine support insulator nuts.
36. If equipped, disconnect the block heater electrical connector and wiring harness retainer.
37. Remove the heater tube bracket bolt.
38. Install the special tool on the RH side of the engine. Tighten to 37 Nm (27 lb-ft).
39. Install the special tool on the LH side of the engine.
40. Attach the special tool and using a suitable floor crane, remove the engine.

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-A) Compressor, Valve Spring 303-581 (T97T-6565-A) Crankshaft Socket 303-674 Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Lifting Eyes 303-050 (D81L-6001-D) or equivalent Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-101 (T74P-3616-A) Remover, Crankshaft Vibration Damper 303-773 Remover, Spark Plug Wire 303-106 (T74P-6666-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

General Equipment

Note. During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or foreign material. Remove all caps, tape and other protective materials prior to installation.

Note. For additional information, refer to the exploded views under Engine .

1. Remove the bolts and the flexplate.
2. Remove the spacer plate and the flexplate spacer.
3. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
4. Install the engine on a suitable stand. Remove the engine lifting equipment and the special tools.
5. Remove the bolt.
6. Disconnect the A/C compressor electrical connector and wire harness retainer.
7. Remove the bolts and the accessory bracket.
8. Disconnect the generator electrical connectors and wire harness retainer.
9. Remove the generator mounting bracket. Remove the bolt and the drive belt tensioner. Remove the generator mounting bracket bolts.
10. Disconnect the heater hose from the thermostat housing.
11. Disconnect the hose from the oil cooler.
12. Remove the bolt, the heater hose tube bracket and the hoses as an assembly.
13. Using the special tool, disconnect the spark plug wires from the spark plugs.
14. Detach the RH spark plug wire retainers.
15. Detach the LH spark plug wire retainers.
16. Disconnect the coil and the radio interference capacitor electrical connectors and detach the wiring harness retainer.
17. Remove the bolts. Remove the coil, bracket and spark plug wires as an assembly.
18. Remove the oil cooler hose bracket bolt, if equipped. Disconnect the oil cooler or heater hose.
19. If equipped, remove the oil cooler and hose.
20. Disconnect the vacuum and PCV hoses from the intake manifold.
21. Disconnect the knock sensor (KS) electrical connector. Detach the wiring harness pin-type retainer.
22. Disconnect the EGR system module vacuum hose and electrical connector. Detach the wiring harness pin-type retainer.
23. Disconnect the electronic throttle body (TB) and throttle position (TP) sensor electrical connectors. Remove the nut and detach the wiring harness bracket.
24. Remove the exhaust manifold-to-EGR system module tube.
25. Remove the bolts and the intake manifold and gaskets.
26. Disconnect the 6 fuel injector electrical connectors and detach the wiring harness retainers.
27. Disconnect the crankshaft position (CKP) sensor electrical connector and the wiring anchors. Discard the wiring anchors.
28. Disconnect the fuel rail pressure and temperature sensor and the camshaft position (CMP) sensor electrical connectors.
29. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
30. Remove the engine wiring harness retainer bolt and remove the engine wiring harness.
31. Disconnect the fuel pressure and temperature sensor vacuum hose fitting. Remove the vacuum harness.
32. Disconnect the oil pressure switch electrical connector, remove the nut and detach the battery cable and harness bracket.
33. Detach the retainers and remove the battery cable and harness.
34. Remove the oil pressure switch.
35. Remove the RH and the LH insulator bolts and brackets.
36. Remove the fuel supply tube bolt.
37. Remove the bolts and the fuel rail.
38. Remove the fuel injectors. Remove and discard the O-ring seals.
39. Loosen the bolts and remove the valve covers.
40. Remove the thermostat housing. Remove the bolts. Release the bypass hose clamp and remove the thermostat housing.
41. Remove the bolt and the oil level indicator tube.
42. Remove the bolt and the KS.
43. Remove the nuts and the RH exhaust manifold and gasket. Discard the nuts and the gasket.
44. Remove and discard the 6 RH exhaust manifold studs.
45. Remove the nuts and the LH exhaust manifold and gasket. Discard the nuts and the gasket.
46. Remove and discard the 6 LH exhaust manifold studs.
47. Using the special tool to hold the crankshaft pulley, remove the bolt.
48. Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley. Discard the crankshaft pulley bolt.
49. Remove the bolts and the coolant pump pulley.
50. Remove the bolts and the coolant pump.
51. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the up position.
52. Using the special tool, remove the camshaft roller followers.
53. Remove the RH hydraulic chain tensioner.
54. Install the special tools on the RH cylinder head and tighten the top 2 clamp bolts. Tighten to 10 Nm (89 lb-in).
55. Remove the RH camshaft sprocket bolt.
56. Remove the bolt.
57. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
58. Remove the LH hydraulic chain tensioner.
59. Install the special tools on the LH cylinder head.
60. Remove the LH camshaft sprocket bolt.
61. Remove the bolt.
62. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
63. Remove the bolts in the sequence shown and remove the cylinder heads. Discard the gaskets and the bolts.
64. Clean and inspect the cylinder head sealing surfaces. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
65. Using the special tool, remove the crankshaft front oil seal.
66. Remove the 5 cylinder block cradle-to-engine front cover bolts.
67. Remove the bolts and the engine front cover.
68. Remove the bolts and the oil pan.
69. Remove the bolt and the oil pump screen cover and tube.
70. Remove the cylinder block cradle inner bolts. Remove and discard the 2 washer seals.
71. Remove the cylinder block cradle Torx bolts.
72. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.
73. Remove the oil pump pickup tube, the oil pump and the oil pump intermediate shaft.
74. Remove the oil filter adapter.
75. Inspect and install new O-ring seals, if necessary.
76. Remove the jackshaft rear plug.
77. Using the special tool, hold the crankshaft.
78. Remove the jackshaft sprocket rear bolt.
79. Remove the RH cassette bolt.
80. Remove the RH cassette.
81. Remove the oil pump bolt and retainer and then remove the oil pump drive.
82. Using the special tool to hold the crankshaft, loosen the front sprocket retaining bolt.
83. Remove the bolts and the chain tensioner.
84. Remove the chain guide.
85. Remove the bolt.
86. Remove the jackshaft and crankshaft sprockets and the chain. Remove the crankshaft key.
87. Remove the bolt and the front cassette.
88. Remove the jackshaft thrust plate.
89. Remove the jackshaft.
90. Remove the balance shaft tensioner. Install a pin in the balance shaft tensioner. Remove the bolts. Remove the balance shaft tensioner.
91. Remove the 2 bolts and the balance shaft chain guide.
92. Remove the balance shaft chain and crankshaft sprocket.
93. Remove the balance shaft. Remove the bolts. Remove the balance shaft.
94. 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 the manufacturer's instructions.
95. Remove the connecting rod caps. Remove the connecting rod cap. Remove the connecting rod nuts.
96. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
97. Remove the connecting rod bearings.
98. Remove the piston rings.
99. Clean and inspect the pistons. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
100. Remove the bolts.
101. Remove the crankshaft main bearing caps.
102. Remove the crankshaft rear oil seal from the crankshaft.
103. Remove the crankshaft.
104. Remove the crankshaft main bearings and the thrust bearing.

1. Position the engine in the vehicle and remove the floor crane and special tool.
2. Install the RH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
3. Remove the special tool from the RH side of the engine.
4. Install the heater tube bracket bolt. Tighten to 34 Nm (25 lb-ft).
5. If equipped, connect the block heater electrical connector and the wiring harness retainer.
6. Remove the special tool from the LH side of the engine.
7. Install the LH engine support insulator through bolt. Tighten to 103 Nm (76 lb-ft).
8. Position the battery cable harness bracket and install the nut. Tighten to 15 Nm (11 lb-ft).
9. Position the transmission cooler tubes and install the nut. Tighten to 23 Nm (17 lb-ft).
10. Install the oil filter. Tighten to 13 Nm (10 lb-ft).
11. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S»(ref-270891) .
12. Attach the starter wiring and install the nuts. Install the terminal cover. Tighten the S-terminal nut to 6 Nm (53 lb-in). Tighten the B-terminal nut to 12 Nm (9 lb-ft).
13. Install a new gasket and a new O-ring seal. Position the A/C tube, install the nut, close the latch and connect the A/C high pressure cutoff switch electrical connector. Tighten to 15 Nm (11 lb-ft).
14. Install new gaskets and new O-ring seal. Position the A/C tubes and install the nuts. Tighten the A/C fitting nuts to 15 Nm (11 lb-ft). Tighten the A/C tube bracket nut to 10 Nm (89 lb-in).
15. Position the evaporative emissions (EVAP) hose and connect it to the EVAP canister purge valve. Connect the EVAP canister purge valve electrical connector.
16. Connect the brake booster vacuum hose.
17. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
18. Position the power steering pressure (PSP) hose and the power steering reservoir-to-power steering pump hoses and install the bolts. Tighten to 11 Nm (8 lb-ft).
19. Connect the power steering pressure switch electrical connector.
20. Connect the lower radiator hose to the coolant pump.
21. Position the power steering pump pulley and install the bolts finger tight.
22. Rotate the accessory drive belt counterclockwise and install the accessory drive belt.
23. Tighten the power steering pump pulley bolts. Tighten to 25 Nm (18 lb-ft).
24. Install the upper radiator hose.
25. Connect the EVAP hose.
26. Position the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
27. Connect the heater hoses and the vacuum hose. Connect the heater control valve vacuum hose.
28. Connect the engine wiring harness-to-PCM electrical connectors and the wiring harness electrical connector. Attach the wiring harness retainer.
29. Position the hood and install the 4 bolts. Tighten to 12 Nm (9 lb-ft).
30. Connect the windshield washer hose.
31. Install the air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
32. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-270902) .
33. Connect the battery cable connectors and install the nuts. Close the cover. Tighten to 12 Nm (9 lb-ft).
34. Connect the electrical connector and attach the wiring harness retainers.
35. Position the ground wire and install the nut. Tighten to 9 Nm (80 lb-in).
36. Connect the battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
37. Connect the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-270952) .
38. Fill the engine with clean engine oil.
39. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-270902) .
40. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-270953) .
41. Start the engine and check for leaks. Stop the engine and check all fluid levels.
42. Carry out the fluid level check for the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S»(ref-270891) .