Engine Mechanical - 3.5L: Other Ford Flex I

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

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ITEM DESCRIPTION CHART

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Exhaust Emission Control System

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

Induction System

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

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

Valve Train

The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Variable Camshaft Timing (VCT) System

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

PCV System

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

Oil Pump

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

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

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

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

Cooling System

The engine cooling system includes the following

1. Radiator
2. Timing chain driven coolant pump
3. Electric fan assembly(s)
4. Degas bottle (aids in maintaining the correct volume of engine coolant)
5. Coolant thermostat
6. Coolant hoses

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

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1. Remove the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-372749-S31798337682010093000000) and «VALVE COVER - RH»(ref-372749-S31810970552010093000000) .
2. NOTE: Engine must be at room temperature before measuring. The valve clearance must be measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft pulley bolt to bring each valve to base circle. Use a feeler gauge to measure the clearance of each valve and record its location. A midrange clearance is the most desirable: Intake: 0.15-0.25 mm (0.006-0.01 in) Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
3. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in). If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
4. If required, install the new selected valve tappets in the marked locations. For additional information, refer to «VALVE TAPPETS»(ref-372749-S23008481062010093000000) .

Upper Intake Manifold

Upper Intake Manifold (View 1 of 2)

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ITEM PART DESCRIPTION CHART

Upper Intake Manifold (View 2 of 2)

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ITEM PART DESCRIPTION CHART

Material

MATERIAL SPECIFICATION CHART

Valve Cover - LH (View 1 of 2)

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ITEM PART DESCRIPTION CHART

Valve Cover - LH (View 2 of 2)

Note. Early build shown in illustration, late build similar.

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

Valve Cover - RH (View 1 of 2)

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ITEM PART DESCRIPTION CHART

Valve Cover - RH (View 2 of 2)

Note. Early build shown in illustration, late build similar.

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the accessory drive belt and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .
3. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

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1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.
3. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

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ITEM PART DESCRIPTION CHART

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

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ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

Valve Tappets

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. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S15507329412010093000000) .
2. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove the valve tappets from the cylinder head.

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MATERIAL SPECIFICATION CHART

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. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

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1. Remove the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S15507329412010093000000) .
2. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
3. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
4. Remove the bolt and the RH CMP sensor.
5. Remove the bolt and the Power Steering Pressure (PSP) tube bracket from the RH cylinder head.
6. Remove the bolt and the ground wire.
7. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
8. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
9. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
10. Remove the 2 LH catalytic converter bracket bolts.
11. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
12. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
13. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
14. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
15. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
16. Remove the 3 bolts and the RH exhaust manifold heat shield.
17. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
18. Clean and inspect the RH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
19. Remove and discard the 6 RH exhaust manifold studs. Engines equipped with early build RH timing chain guides
20. Remove the 2 bolts and the RH primary timing chain guide. Engines equipped with late build/replacement RH timing chain guides
21. Remove the 2 bolts and the RH primary timing chain guide. All vehicles
22. Remove the bolts and the RH secondary timing chain tensioner.
23. Remove the 2 bolts and the engine lifting eye.
24. NOTE: Index-mark the location of the bracket on the cylinder head for installation. Remove the bolt and the upper intake manifold support bracket.
25. Remove the coolant bypass hose from the thermostat housing.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
28. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
29. Disconnect and remove the CHT sensor jumper harness.
30. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove the valve tappets from the cylinder head.
31. Inspect the valve tappets. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
32. Remove and discard the M6 bolt.
33. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
34. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
35. 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-372759) .

MATERIAL SPECIFICATION CHART

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.

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1. Remove the LH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S15507329412010093000000) .
2. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
3. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the LH CMP sensor.
6. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
7. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
8. Detach the wiring harness retainer from the rear of the LH cylinder head.
9. Remove the nut and disconnect the generator B+ cable.
10. Disconnect the generator electrical connector.
11. Remove the nut, bolt and the generator. Remove the generator stud.
12. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
13. Remove the 2 LH catalytic converter bracket bolts.
14. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
15. Remove the 3 bolts and the LH exhaust manifold heat shield.
16. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
17. Clean and inspect the LH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
18. Remove and discard the 6 LH exhaust manifold studs.
19. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
20. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
21. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
22. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
23. Remove the coolant bypass hose from the thermostat housing.
24. Remove the 4 bolts and the fuel rail and injectors as an assembly.
25. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
26. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
27. Remove the 2 bolts and the upper LH primary timing chain guide.
28. Remove the 2 bolts and the LH secondary timing chain tensioner.
29. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove the valve tappets from the cylinder head.
30. Inspect the valve tappets. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
31. Remove and discard the M6 bolt.
32. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
33. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
34. 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-372759) .

MATERIAL SPECIFICATION CHART

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. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

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1. Remove the engine from the vehicle. For additional information, refer to «ENGINE»(ref-372749-S00800139992010093000000) .
2. Remove the 8 bolts and the flywheel.
3. Remove the crankshaft sensor ring.
4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
6. Disconnect the PCV hose from the PCV valve.
7. Disconnect the Throttle Body (TB) electrical connector.
8. Detach the wiring harness retainers from the upper intake manifold.
9. Remove the upper intake manifold support bracket bolt.
10. Remove the fuel tube bracket bolt from the upper intake manifold.
11. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
12. Disconnect the Power Steering Pressure (PSP) switch electrical connector. Front Wheel Drive (FWD) vehicles
13. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector. All vehicles
14. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
15. Disconnect the 3 RH coil-on-plug electrical connectors.
16. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
18. Disconnect the LH CMS electrical connector.
19. Disconnect the LH VCT solenoid electrical connector.
20. Disconnect the 3 LH coil-on-plug electrical connectors.
21. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
22. NOTE: LH shown in illustration, RH similar. Remove the 6 bolts and the 6 coil-on-plugs.
23. NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan. Remove the A/C compressor nut and stud.
24. Remove the PSP tube bracket-to-power steering pump bolt.
25. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
26. Remove the 3 bolts and position aside the power steering pump.
27. Remove the 3 bolts and the accessory drive belt tensioner.
28. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket. FWD vehicles
29. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket. All vehicles
30. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
31. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block. Early build vehicles
32. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
33. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
34. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
35. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
36. NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
37. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
38. Using the 3 Jaw Puller, remove the crankshaft pulley.
39. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
40. Remove the 2 bolts and the engine mount bracket.
41. NOTE: Only use hand tools to remove the studs. Remove the 2 engine mount studs.
42. Remove the 3 bolts and the engine mount bracket.
43. Remove the 22 engine front cover bolts.
44. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
45. Remove the 16 oil pan bolts.
46. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
47. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths. Clean the engine front cover and oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
48. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Oil Pump Screen and Pickup Tube

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 oil pan. For additional information, refer to «OIL PAN»(ref-372749-S14251943112010093000000) .
2. Remove the 2 bolts and the oil pump screen and pickup tube.

1. Discard the O-ring seal.

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MATERIAL SPECIFICATION CHART

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. This procedure is for removal of the crankshaft rear seal and retainer plate and requires removal of the oil pan. If only removing the crankshaft rear seal, refer to CRANKSHAFT REAR SEAL .

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-372749-S14251943112010093000000) .
2. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
3. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
4. Remove the bolt and the CKP sensor.
5. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
6. Remove the 8 crankshaft rear seal retainer bolts.
7. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
8. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths. Clean the crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
9. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

MATERIAL SPECIFICATION CHART

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. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage tot he valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

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

All vehicles

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1. Remove the 8 bolts and the flexplate.
2. Remove the crankshaft sensor ring.
3. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
6. Disconnect the PCV hose from the PCV valve.
7. Disconnect the Throttle Body (TB) electrical connector.
8. Detach the wiring harness retainers from the upper intake manifold.
9. Remove the upper intake manifold support bracket bolt.
10. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
11. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
12. Disconnect the Power Steering Pressure (PSP) switch electrical connector. Front Wheel Drive (FWD) vehicles
13. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector. All vehicles
14. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
15. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
16. Disconnect the 3 RH coil-on-plug electrical connectors.
17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
18. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
19. Disconnect the Knock Sensor (KS) electrical connector.
20. Remove the bolt and the ground cable from the RH cylinder.
21. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
22. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
23. Disconnect the LH CMP sensor electrical connector.
24. Disconnect the LH CMS electrical connector.
25. Disconnect the LH HO2S electrical connector.
26. Disconnect the 3 LH coil-on-plug electrical connectors.
27. Disconnect the LH VCT solenoid electrical connector.
28. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
29. Remove the nut, the bolt and the heat shield.
30. Remove the wiring harness retainer stud bolt.
31. Remove the wiring harness grommet.
32. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
33. Disconnect the A/C compressor electrical connector. Detach the A/C compressor wiring harness retainer.
34. Remove the nut and disconnect the generator B+ cable.
35. Disconnect the generator electrical connector.
36. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
37. Remove the nut, 2 bolts and the A/C compressor.
38. Remove the A/C compressor mounting stud from the oil pan.
39. Remove the nut, bolt and the generator. Remove the generator stud.
40. Remove the PSP tube bracket-to-power steering pump bolt.
41. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
42. Remove the bolt and the PSP tube bracket from the RH cylinder head.
43. Remove the 3 bolts and position aside the power steering pump.
44. Remove the 3 bolts and the accessory drive belt tensioner.
45. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
46. Remove the 3 bolts and the LH exhaust manifold heat shield.
47. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
48. Clean and inspect the LH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
49. Remove and discard the 6 LH exhaust manifold studs. FWD vehicles
50. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket. All vehicles
51. Remove the 3 bolts and the RH exhaust manifold heat shield.
52. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
53. Clean and inspect the RH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
54. Remove and discard the 6 RH exhaust manifold studs.
55. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
56. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
57. Remove the pin-type retainer and the cover.
58. Remove the 2 bolts and the engine lifting eye.
59. Remove the bolt and the upper intake manifold support bracket.
60. Remove the bolt and the RH CMP sensor.
61. Remove the coolant bypass hose from the thermostat housing.
62. Remove the 4 bolts and the fuel rail and injectors as an assembly.
63. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket.
64. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
65. Disconnect and remove the CHT sensor jumper harness.
66. Remove the bolt and the LH CMP sensor.
67. Remove the bolt and the CKP sensor.
68. NOTE: A new oil cooler must be installed or severe damage to the engine can occur. If equipped, remove the 6 bolts (4 shown in illustration) and the oil cooler. Discard the oil cooler and the gaskets.
69. NOTE: Engine without oil cooler shown in illustration, engine with oil cooler similar. Remove the 3 bolts and the oil filter adapter. Discard the gasket.
70. Remove the EOP switch.
71. NOTE: LH shown in illustration, RH similar. Remove the 6 bolts and the 6 coil-on-plugs. Early build vehicles
72. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
73. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
74. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
75. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
76. NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal similar. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
77. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
78. Using the 3 Jaw Puller, remove the crankshaft pulley.
79. Using the Oil Seal Remover, remove and discard the crankshaft pulley front seal.
80. Remove the 2 bolts and the engine mount bracket.
81. NOTE: Only use hand tools to remove the studs. Remove the 2 engine mount studs.
82. Remove the 3 bolts and the engine mount bracket.
83. Remove the 22 engine front cover bolts.
84. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover. Engines equipped with early build RH timing chain guides
85. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
86. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
87. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
88. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
89. Remove the 3 bolts and the RH VCT housing.
90. Remove the 3 bolts and the LH VCT housing.
91. Remove the 2 bolts and the primary timing chain tensioner.
92. Remove the primary timing chain tensioner arm.
93. Remove the 2 bolts and the lower LH primary timing chain guide.
94. Remove the primary timing chain.
95. Remove the crankshaft timing chain sprocket.
96. Remove the 2 bolts and the upper LH primary timing chain guide.
97. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
98. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
99. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position. Remove the Camshaft Holding Tool from the LH camshafts.
100. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur. Verify the LH camshafts are in the neutral position.
101. Remove the 2 bolts and the LH secondary timing chain tensioner.
102. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
103. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
104. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
105. Remove the Camshaft Holding Tool from the RH camshafts.
106. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur. Rotate the RH camshafts counterclockwise to the neutral position.
107. Remove the 2 bolts and the RH secondary timing chain tensioner. Engines equipped with early build RH timing chain guides
108. Remove the 2 bolts and the RH primary timing chain guide. Engines equipped with late build/replacement RH timing chain guides
109. Remove the 2 bolts and the RH primary timing chain guide. All vehicles
110. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.
111. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. NOTE: LH shown in illustration, RH similar. Remove the valve tappets from the cylinder heads.
112. NOTE: LH shown in illustration, RH similar. Remove and discard the M6 bolt from each cylinder head.
113. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. NOTE: LH shown in illustration, RH similar. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
114. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
115. 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-372759) .
116. Remove the coolant inlet tube. Remove and discard the O-ring seals.
117. Remove the 2 bolts and the KS .
118. Remove the 8 bolts and the coolant pump.
119. Remove the 16 oil pan bolts.
120. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
121. Remove the 2 bolts and the oil pump screen and the pickup tube. Discard the O-ring seal.
122. Remove the 3 bolts and the oil pump.
123. Remove the 8 crankshaft rear seal retainer bolts.
124. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
125. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
126. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
127. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Remove the bolts in the sequence shown in illustration. Remove the main bearing cap support brace. Discard the bolts.
128. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement. NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly. Remove the connecting rod cap bolts and cap.
129. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Remove the piston/rod assembly from the engine block.
130. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
131. NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration. Discard the bolts.
132. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly. NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap. Remove the 4 main bearing caps.
133. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead. Remove the crankshaft.
134. NOTE: Inside shown in illustration, outside similar. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
135. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly. Remove the 4 crankshaft main bearings from the cylinder block.
136. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly. Remove the 4 crankshaft main bearings from the main bearing caps.
137. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
138. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.

MATERIAL SPECIFICATION CHART

Scheme 336

ITEM PART DESCRIPTION CHART

MATERIAL SPECIFICATION CHART

Scheme 337

ITEM PART DESCRIPTION CHART

Scheme 338

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin. Discard the 2 piston pin retainer clips.
3. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for reassembly. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .

MATERIAL SPECIFICATION CHART

Scheme 339

ITEM PART DESCRIPTION CHART

Scheme 340

ITEM PART DESCRIPTION CHART

Scheme 341

ITEM PART DESCRIPTION CHART

Engine Front

Note. Early build engines shown in illustration, late build similar.

Scheme 342

ITEM PART DESCRIPTION CHART

Scheme 343

ITEM PART DESCRIPTION CHART

Scheme 344

ITEM PART DESCRIPTION CHART

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. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

All vehicles

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1. NOTE: This procedure is for selecting bearings using a new crankshaft. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block face. The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. If the block code is *BM*QS* and the crankshaft code is *OL*PO*, Main No. 1 should be built with grade 1 bearings, as determined by the intersection of the B block column and the O crankshaft row on the chart. Mains No. 2, No. 3 and No. 4 should all be grade 2.
3. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting rod caps and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
4. Measure the connecting rod large end bore in 2 directions. Remove the bolts and the rod cap. Discard the connecting rod cap bolts.
5. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
6. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
7. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
8. NOTE: Do not install the upper thrust bearings until the crankshaft is installed. NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil. Install the crankshaft onto the upper main bearings.
9. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
10. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.
11. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
12. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
13. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer. Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.
14. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
15. Loosen the No. 4 main bearing cap bolts.
16. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers. Tighten the main bearing bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 60 Nm (44 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
17. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
19. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Prepare the connecting rod and cap. Insert the new bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap.
20. Before installing the pistons into the cylinder block, verify proper ring gap location. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location
21. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to «DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES»(ref-372749-S02286435332010093000000) - Piston. NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled. Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
22. Seat the connecting rod on the crankshaft journal.
23. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation. Install the connecting rod cap and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
24. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
25. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps. Stage 1: Tighten fasteners to 20 Nm (177 lb-in). Stage 2: Tighten fasteners an additional 180 degrees.
26. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
27. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
28. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
29. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
30. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan. Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
31. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
32. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown in illustration to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
33. Align the oil pan to the cylinder block and A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown in illustration.
34. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration to 3 Nm (27 lb-in).
35. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration. Tighten the large bolts (1-14) to 20 Nm (177 lb-in). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
36. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
37. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
38. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
39. NOTE: Apply clean engine coolant to the O-ring seals prior to installation. Using new O-ring seals, install the coolant inlet tube.
40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
41. Install the bolt. Tighten to 10 Nm (89 lb-in).
42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
43. Install the bolt. Tighten to 10 Nm (89 lb-in).
44. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage. Position the crankshaft dowel pin in the 9 o'clock position.
45. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. NOTE: LH shown in illustration, RH similar. Install the valve tappets.
46. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
47. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
48. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
49. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
50. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-372749-S23648534222010093000000) . Engines equipped with early build RH timing chain guides
51. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with late build/replacement RH timing chain guides
52. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
53. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
54. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.
55. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
56. Position the RH secondary timing assembly onto the camshafts.
57. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
58. Remove the lockpin from the RH secondary timing chain tensioner.
59. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
60. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Rotate the LH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.
61. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
62. Position the LH secondary timing assembly onto the camshafts.
63. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
64. Remove the lockpin from the LH secondary timing chain tensioner.
65. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
66. Install the crankshaft timing chain sprocket.
67. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
68. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
69. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
70. Install the primary timing chain tensioner arm.
71. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
72. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
73. As a post-check, verify correct alignment of all timing marks.
74. Inspect the VCT housing seals for damage and replace as necessary.
75. NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
76. NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
77. Install the Alignment Pins.
78. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
79. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
80. Remove the Alignment Pins.
81. NOTE: Do not tighten the bolts at this time. Install the engine mount bracket and the 3 bolts.
82. NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
83. NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in).
84. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
85. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover. Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
86. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil. Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.
87. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
88. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, VCT solenoid seal installation similar. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
89. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints. Early build vehicles
90. Using a new gasket, install the RH valve cover and tighten the bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
91. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
92. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints. Early build vehicles
93. Using a new gasket, install the LH valve cover and tighten the 11 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
94. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
95. NOTE: LH shown in illustration, RH similar. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
96. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads. Install the EOP switch. Tighten to 18 Nm (159 lb-in).
97. NOTE: Engine without oil cooler shown in illustration, engine with oil cooler similar. Using a new gasket, install the oil filter adapter and 3 bolts. Tighten to 10 Nm (89 lb-in).
98. NOTE: A new oil cooler must be installed or severe damage to the engine may occur. If equipped, install a new oil cooler, new gaskets and the 6 bolts. Tighten in sequence shown in illustration to 10 Nm (89 lb-in).
99. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
100. Install LH Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
101. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
102. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
103. Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
104. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
105. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
106. Install the coolant bypass hose to the thermostat housing.
107. Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
108. NOTE: Align the bracket with the index mark made during removal. Install the upper intake manifold support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
109. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
110. Install the cover and the pin-type retainer.
111. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
112. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
113. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
114. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
115. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in). Front Wheel Drive (FWD) vehicles
116. Using a new gasket, install the RH catalytic converter and the 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
117. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
118. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
119. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
120. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
121. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
122. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
123. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
124. Install the PSP tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
125. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
126. Install the stud, generator and the nut and the bolt. Tighten the generator stud to 12 Nm (106 lb-in). Tighten nut and bolt to 48 Nm (35 lb-ft).
127. Position the wiring harness onto the engine.
128. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
129. Connect the generator electrical connector.
130. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
131. Connect the A/C compressor electrical connector. Attach the A/C compressor wiring harness retainer.
132. Connect the CKP sensor electrical connector.
133. Install the wiring harness grommet.
134. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
135. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
136. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
137. Connect the LH camshaft VCT solenoid electrical connector.
138. Connect the 3 LH coil-on-plug electrical connectors.
139. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
140. Connect the LH CMS electrical connector.
141. Connect the LH CMP sensor electrical connector.
142. Connect the CHT sensor electrical connector.
143. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
144. Install the RH cylinder head ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
145. Connect the KS electrical connector.
146. Connect the RH CMP sensor electrical connector.
147. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
148. Connect the 3 RH coil-on-plug electrical connectors.
149. Connect the RH VCT solenoid electrical connector.
150. Connect the RH HO2S electrical connector. FWD vehicles
151. Connect the RH CMS electrical connector. All vehicles
152. Connect the PSP switch electrical connector.
153. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
154. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer. Tighten to 6 Nm (53 lb-in).
155. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
156. Attach the wiring harness retainers to the upper intake manifold.
157. Connect the Throttle Body (TB) electrical connector.
158. Connect the PCV hose to the PCV valve.
159. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
160. If equipped, connect the block heater electrical connector and install the heat shield.
161. Install the Engine Lift Eye on the LH cylinder head.
162. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
163. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
164. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
165. Install the crankshaft sensor ring.
166. Install the flexplate and the 8 bolts.

1. Tighten to 80 Nm (59 lb-ft).

MATERIAL SPECIFICATION CHART

All vehicles

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

1. Using the Heavy Duty Floor Crane and Spreader Bar, align the transaxle to the engine.
2. Install the 5 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
5. NOTE: Position a block of wood under the transaxle. Install the Powertrain Lift and Universal Adapter Brackets.
6. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
7. Connect the transaxle control electrical connector.
8. Install the starter, the stud bolt and bolt. Tighten to 27 Nm (20 lb-ft).
9. Connect the wiring harness retainer to the starter motor stud bolt.
10. Attach the starter wire terminals and install the 2 nuts. Tighten the B+ terminal nut to 12 Nm (106 lb-in). Tighten the S-terminal nut to 5 Nm (44 lb-in).
11. Install the starter motor solenoid cover.
12. Raise the engine and transaxle assembly into the vehicle.
13. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
14. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
15. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
16. Install the transaxle support insulator bracket, 3 nuts and the bolt. Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft). Tighten the transaxle support insulator bolt to 80 Nm (59 lb-ft).
17. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft). All-Wheel Drive (AWD) vehicles
18. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle. Using a small screw driver, remove the compression seal and discard.
19. Using a soft face hammer, install the new compression seal.
20. Position the PTU in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
21. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
22. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
23. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
24. NOTE: A new Power Transfer Unit (PTU) shaft seal must be installed whenever the intermediate shaft is removed or damage to the components can occur. Install a new intermediate shaft seal and deflector. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-372778) . All vehicles
25. Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
26. Install 3 new torque converter bolts. Tighten to 55 Nm (41 lb-ft).
27. Install the inspection cover and the 2 fasteners.
28. Connect the transaxle cooler tubes and install the 2 secondary latches.
29. If equipped, connect the oil cooler coolant hoses.
30. Install the RH halfshaft support bracket and the 4 bolts. Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft). Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (177 lb-in).
31. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
32. NOTE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur. Install the correct new circlip on the inboard stub shaft.
33. NOTE: After insertion, pull the halfshaft inner end to make sure the circlip is locked. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
34. Rotate the LH wheel knuckle into position and insert the LH halfshaft into the wheel hub.
35. Install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
36. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
37. Using the Powertrain Lift, raise the subframe into the installed position.
38. NOTE: RH shown in illustration, LH similar. Install the 2 front subframe bolts. Tighten to 200 Nm (148 lb-ft).
39. NOTE: RH shown in illustration, LH similar. Position the subframe brackets and install the 4 bolts finger-tight.
40. NOTE: RH shown in illustration, LH similar. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
41. NOTE: RH shown in illustration, LH similar. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
42. NOTE: RH shown in illustration, LH similar. Position the ball joints into the wheel knuckles. Install the new ball joint nuts. Tighten to 200 Nm (148 lb-ft).
43. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts. NOTE: RH shown in illustration, LH similar. Install new tie-rod end nuts. Tighten to 150 Nm (111 lb-ft).
44. NOTE: RH shown in illustration, LH similar. Install new upper stabilizer bar link nuts. Tighten to 150 Nm (111 lb-ft).
45. Install the 2 front engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
46. Install the 2 rear engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
47. Using a new O-ring seal, install the Power Steering Pressure (PSP) tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
48. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
49. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees. AWD vehicles
50. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts. Tighten to 70 Nm (52 lb-ft). All vehicles
51. Using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
52. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
53. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-372796) . NOTE: Align the index marks made during removal. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
54. Position the RH brake hose bracket and install the bolt. Tighten to 30 Nm (22 lb-ft).
55. Position the rubber shield and install the 2 lower scrivets.
56. NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. NOTE: RH shown in illustration, LH similar. Using the previously removed RH and LH wheel hub nuts, seat the halfshaft. Tighten to 350 Nm (258 lb-ft). Remove and discard the wheel hub nuts.
57. NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. NOTE: Apply the brake to keep the halfshaft from rotating. NOTE: RH shown in illustration, LH similar. Install a new RH and LH wheel hub nut. Tighten to 350 Nm (258 lb-ft).
58. Connect the hose to the power steering reservoir.
59. Install the ground cable and bolt. Tighten to 12 Nm (106 lb-in).
60. Attach the wire to the RH valve cover stud bolt.
61. Attach the engine wiring harness retainer.
62. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
63. Using a new O-ring seal, connect the upper A/C tube to the condenser, install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (133 lb-in).
64. If equipped, attach the engine block heater harness to the radiator support.
65. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
66. Connect the transaxle control cable to the control lever.
67. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
68. Install the engine wiring harness retainer to the bulkhead. Slide the wiring harness in the bulkhead. Make sure the wiring harness retainer tab is below the bulkhead lip.
69. Connect the 2 PCM electrical connectors.
70. Connect the PCM and engine harness electrical connectors. Attach the wiring harness retainer.
71. Install the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
72. Attach the EVAP tube pin-type retainer to the upper intake manifold.
73. Connect the vacuum hose and the EVAP tube from the upper intake manifold.
74. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-372804) .
75. Using a new O-ring seal and gasket seal, install the A/C tube and the nut. Tighten to 15 Nm (133 lb-in).
76. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut. Tighten to 15 Nm (133 lb-in).
77. Connect the power steering cooler tube.
78. Install the front valance, 3 pin-type retainers and 7 bolts.
79. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-372765) .
80. Install the LF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-372756) .
81. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
82. Connect the 2 power feed wires to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
83. Connect the engine wiring harness electrical connector.
84. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
85. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
86. Install the strut tower brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
87. Attach the brake booster vacuum hose retainers to the strut tower brace.
88. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-372798) .
89. Fill the engine with clean engine oil.
90. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-372804) .
91. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS)»(ref-372763) .
92. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

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. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. Install the valve tappets.
2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S33556145182010093000000) .

MATERIAL SPECIFICATION CHART

1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-372749-S42703490172010093000000) .

MATERIAL SPECIFICATION CHART

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. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late built engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

Scheme 395

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
3. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. Install the valve tappets.
4. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
5. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
6. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
7. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
8. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
9. Install the coolant bypass hose to the thermostat housing.
10. NOTE: Align the bracket with the index mark made during removal. Install the upper intake manifold support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
11. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
12. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with late build/replacement RH timing chain guides
13. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with early build RH timing chain guides
14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
15. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
16. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
17. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
18. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
19. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
20. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
21. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
22. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
23. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
24. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
25. Connect the CHT sensor electrical connector.
26. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
27. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
28. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
29. Install the RH Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
30. Connect the RH CMP sensor electrical connector.
31. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
32. Install the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S33556145182010093000000) .

MATERIAL SPECIFICATION CHART

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 396

1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
3. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. Install the valve tappets.
4. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
5. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
7. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
8. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
9. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the coolant bypass hose to the thermostat housing.
11. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
12. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
13. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
14. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
15. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
16. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
17. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
18. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
19. Install the LH catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
20. Attach the Engine Oil Pressure (EOP) switch wiring harness pin-type retainer.
21. Install the stud, generator and the nut and bolt. Tighten the stud to 12 Nm (106 lb-in). Tighten the nut and bolt to 48 Nm (35 lb-ft).
22. Connect the generator electrical connector.
23. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
24. Attach the pin-type wire harness retainer to the rear of LH cylinder head.
25. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
26. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
27. Install the LH Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
28. Connect the LH CMP sensor electrical connector.
29. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
30. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
31. Install the LH camshafts. For additional information, refer to «CAMSHAFT»(ref-372749-S33556145182010093000000) .

MATERIAL SPECIFICATION CHART

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. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

1. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
2. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application. Install the oil pan and bolts 10, 11, 13 and 14. Tighten in the sequence shown in illustration to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
3. Align the oil pan to the cylinder block and A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown in illustration.
4. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration, to 3 Nm (27 lb-in).
5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration. Tighten the large bolts (1-14) to 20 Nm (177 lb-in). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
6. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
7. Install the Alignment Pins.
8. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
9. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence shown in illustration to 3 Nm (27 lb-in).
10. Remove the Alignment Pins.
11. NOTE: Do not tighten the bolts at this time. Install the engine mount bracket and the 3 bolts.
12. NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
13. NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in).
14. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
15. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover. Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
16. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil. Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.
17. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
18. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, Variable Camshaft Timing (VCT) solenoid seal installation similar. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
19. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints. Early build vehicles
20. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
21. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
22. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints. Early build vehicles
23. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
24. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
25. NOTE: LH shown in illustration, RH similar. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
26. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
27. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft). Front Wheel Drive (FWD) vehicles
28. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
29. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
30. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
31. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
32. Install the Power Steering Pressure (PSP) tube bracket bolt. Tighten to 10 Nm (89 lb-in).
33. Install the PSP bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
34. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
35. Connect the 3 LH coil-on-plug electrical connectors.
36. Connect the LH camshaft VCT solenoid electrical connector.
37. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
38. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
39. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
40. Connect the 3 RH coil-on-plug electrical connectors.
41. Connect the RH VCT solenoid electrical connector. FWD vehicles
42. Connect the RH CMS electrical connector. All vehicles
43. Connect the PSP switch electrical connector.
44. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
45. Install the fuel tube bracket bolt to the upper intake manifold. Tighten to 6 Nm (53 lb-in).
46. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
47. Attach the wiring harness retainers to the upper intake manifold.
48. Connect the Throttle Body (TB) electrical connector.
49. Connect the PCV hose to the PCV valve.
50. If equipped, connect the block heater electrical connector and install the heat shield. Attach all the engine block heater wiring harness retainer.
51. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
52. Install the crankshaft sensor ring.
53. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
54. Install the engine in the vehicle. For additional information, refer to «ENGINE»(ref-372749-S39379037132010093000000) .

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.

1. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the oil pan. For additional information, refer to «OIL PAN»(ref-372749-S14947649812010093000000) .

MATERIAL SPECIFICATION CHART

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.

1. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
2. Install the rear seal retainer and the 8 bolts in the sequence shown in illustration. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
3. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
4. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
5. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
6. Connect the CKP sensor electrical connector.
7. Using the Heavy Duty Floor Crane and Spreader Bar, install the engine onto the stand.
8. Install the oil pan. For additional information, refer to «OIL PAN»(ref-372749-S14947649812010093000000) .