Engine Mechanical - 3.5L: Removal & Installation Ford Flex I

Removal

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
2. Disconnect the Throttle Body (TB) electrical connector.
3. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
4. Detach the EVAP tube pin-type retainer from the upper intake manifold.
5. Disconnect the brake booster vacuum hose from the intake manifold.
6. Disconnect the PCV tube from the PCV valve.
7. Detach the wiring harness retainers from the upper intake manifold.
8. Remove the upper intake manifold support bracket bolt.
9. Remove the fuel tube bracket bolt.
10. Remove the 6 bolts and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

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1. 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).
2. Install the fuel tube bracket bolt. Tighten to 6 Nm (53 lb-in).
3. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
4. Attach the wiring harness retainers to the upper intake manifold.
5. Connect the PCV tube to the PCV valve.
6. Connect the brake booster vacuum hose to the intake manifold.
7. Connect the EVAP tube to the intake manifold.
8. Attach the EVAP tube pin-type retainer to the upper intake manifold.
9. Connect the TB electrical connector.
10. Install the ACL outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .

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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.

1. Remove the fuel rail. For additional information, Refer to «FUEL CHARGING AND CONTROLS - 3.5L/3.5L GTDI»(ref-372807) .
2. Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
3. Remove the 3 thermostat housing-to-lower intake manifold bolts.
4. Remove the 10 bolts and the lower intake manifold.

1. Remove and discard the intake manifold and thermostat housing gaskets.
2. Clean and inspect all sealing surfaces.

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1. 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 intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Install the 3 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
3. Install the fuel rail. For additional information, Refer to «FUEL CHARGING AND CONTROLS - 3.5L/3.5L GTDI»(ref-372807) .
4. Fill and bleed the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .

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 LH ignition coils. For additional information, Refer to «ENGINE IGNITION - 3.5L/3.5L GTDI»(ref-372805) .
2. Remove the oil level indicator.
3. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.
4. Detach all of the wiring harness retainers from the LH valve cover stud bolts.
5. Disconnect the 3 LH fuel injector electrical connectors. Early build vehicles
6. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket. Late build vehicles
7. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket. All vehicles
8. 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).
9. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

Installation

All vehicles

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1. 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.
2. NOTE: Failure to use the correct 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. Late build vehicles
3. 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). Early build vehicles
4. 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). All vehicles
5. Connect the 3 LH fuel injector electrical connectors.
6. Attach all of the wiring harness retainers to the LH valve cover stud bolts.
7. Connect the LH VCT solenoid electrical connector.
8. Install the oil level indicator.
9. Install the LH ignition coils. For additional information, Refer to «ENGINE IGNITION - 3.5L/3.5L GTDI»(ref-372805) .

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. Remove the RH ignition coils. For additional information, Refer to «ENGINE IGNITION - 3.5L/3.5L GTDI»(ref-372805) .
2. Detach and disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
3. Detach and disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
4. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
5. Disconnect the 3 RH fuel injector electrical connectors.
6. Detach all of the wiring harness retainers from the RH valve cover stud bolts.
7. Remove the nut and the Power Steering Pressure (PSP) tube bracket from the valve cover stud bolt. Early build vehicles
8. NOTE: It is necessary to reposition the A/C tubes to remove the valve cover. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
9. NOTE: It is necessary to reposition the A/C tubes to remove the valve cover. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
10. 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).
11. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

All vehicles

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1. 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 a new VCT solenoid and/or spark plug tube seals.
2. 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. Late build vehicles
3. 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). Early build vehicles
4. 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). All vehicles
5. Install the PSP tube bracket on the valve cover stud bolt and install the nut. Tighten to 7 Nm (62 lb-in).
6. Attach all of the wiring harness retainers to the RH valve cover stud bolts.
7. Connect the 3 RH fuel injector electrical connectors.
8. Connect the RH VCT solenoid electrical connector.
9. Connect the RH CMS electrical connector.
10. Connect the RH HO2S electrical connector.
11. Install the RH ignition coils. For additional information, Refer to «ENGINE IGNITION - 3.5L/3.5L GTDI»(ref-372805) .

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ITEM PART DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-372749-S07112943522010093000000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

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1. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-372749-S07112943522010093000000) .

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ITEM PART DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the transaxle. For additional information, Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50/6F55»(ref-372752) .
3. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-372749-S37286541482010093000000) .
3. Remove the crankshaft sensor ring.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.

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1. 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.
2. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
3. Install the crankshaft sensor ring.
4. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-372749-S37286541482010093000000) .

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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Recover the A/C system. For additional information, Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .
3. Remove the Air Cleaner (ACL) outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
4. Remove the front wheels and tires. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .
6. Remove the degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
7. Remove the Evaporative Emission (EVAP) canister purge valve. For additional information, Refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
8. Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
9. Remove the nut and the A/C tube. Discard the O-ring seal and gasket seal.
10. Remove the nut and disconnect the rear A/C tube. Discard the O-ring seal and gasket seal.
11. Working from under the vehicle, remove the nut and disconnect the rear A/C tube. Discard the O-ring seal and gasket seal.
12. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
13. Remove the RH inner fender splash shield. For additional information, Refer to «FRONT END BODY PANELS»(ref-372798) .
14. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
15. Using the 3 Jaw Puller, remove the crankshaft pulley.
16. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
17. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
18. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
19. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
20. Disconnect the hose from the power steering reservoir.
21. Remove the RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-372749-S31798337682010093000000) and «VALVE COVER - RH»(ref-372749-S31810970552010093000000) .
22. Remove the bolt and the ground cable.
23. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
24. Remove the PSP tube bracket-to-power steering pump bolt.
25. Remove the 3 bolts and position aside the power steering pump.
26. NOTE: The Oil Pan Holding Fixture must be carefully aligned to the mounting bosses on the oil pan. Failure to follow these instructions may result in damage to the oil pan. Position a floor jack and the Oil Pan Holding Fixture under the oil pan.
27. Remove the nut, bolt and engine mount brace.
28. Remove the 4 engine mount nuts.
29. Remove the 3 bolts and the engine mount.
30. Remove the 2 bolts and the engine mount bracket.
31. NOTE: Only use hand tools to remove the studs. Remove the 2 engine mount studs.
32. Remove the 2 upper engine mount bracket bolts.
33. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
34. Detach the A/C tube and wiring harness from the retainers.
35. Remove the A/C tube bracket bolt.
36. Remove the A/C tube retaining clamp bolt.
37. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes as an assembly. Discard the O-ring seals.
38. Using the floor jack, raise the engine slightly.
39. Remove the 22 engine front cover bolts.
40. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.

1. 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.

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1. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. 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 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 to remove any foreign material, including any abrasive particles created during the cleaning process.
2. 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, including any sealant from the inner surface of the cylinder block and cylinder head. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan 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.
3. Install the Alignment Pins.
4. 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.
5. 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).
6. Remove the Alignment Pins.
7. Install the engine mount bracket and lower bolt. Do not tighten at this time.
8. Install the 2 upper engine mount bracket bolts. Do not tighten at this time.
9. 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).
10. Using the floor jack, lower the engine to the installed position.
11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt. Tighten to 15 Nm (133 lb-in).
12. Install the A/C tube retaining clamp bolt. Tighten to 9 Nm (80 lb-in).
13. Install the A/C tube bracket bolt. Tighten to 10 Nm (89 lb-in).
14. Attach the A/C tube and wiring harness to the retainers.
15. 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).
16. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
17. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
18. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
19. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
20. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
21. Install the PSP tube bracket-to-power steering pump bolt. Tighten to 10 Nm (89 lb-in).
22. Connect the PSP switch electrical connector.
23. Install the ground cable bolt. Tighten to 12 Nm (106 lb-in).
24. Install the RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-372749-S31798337682010093000000) and «VALVE COVER - RH»(ref-372749-S31810970552010093000000) .
25. Connect the hose to the power steering reservoir.
26. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
27. Install the exhaust Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
28. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
29. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
30. 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.
31. Install the RH inner fender splash shield. For additional information, Refer to «FRONT END BODY PANELS»(ref-372798) .
32. Connect the power steering cooler tube.
33. Using a new O-ring seal and gasket seal, install the A/C tube and nut. Tighten to 15 Nm (133 lb-in).
34. Using a new O-ring seal and gasket seal, install the A/C tube and nut. Tighten to 15 Nm (133 lb-in).
35. Using a new O-ring seal and gasket seal, install the A/C tube and nut. Tighten to 15 Nm (133 lb-in).
36. 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).
37. Install the EVAP canister purge valve. For additional information, Refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
38. Install the degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
39. Install the accessory drive belt, tensioner and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .
40. Install the front wheels and tires. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
41. Install the engine ACL outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
42. 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. Fill the engine with clean engine oil.
43. Fill the power steering system. For additional information, Refer to «STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS)»(ref-372763) .
44. Recharge the A/C system. For additional information, Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .

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 engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-372749-S10820801042010093000000) . Engines equipped with early build RH timing chain guides
2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
3. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
4. 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.
5. 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.
6. Remove the 3 bolts and the RH VCT housing.
7. Remove the 3 bolts and the LH VCT housing.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 bolts and the upper LH primary timing chain guide.
14. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
15. 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 LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
16. NOTE: It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt. Remove the 2 bolts and the LH secondary timing chain tensioner.
17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
18. 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.
19. NOTE: It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt. Remove the 2 bolts and the RH secondary timing chain tensioner. 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.

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Engines equipped with late build/replacement RH timing chain guides

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1. 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
2. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
3. NOTE: It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
4. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
5. Position the RH secondary timing assembly onto the camshafts.
6. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. 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.
7. Remove the lockpin from the RH secondary timing chain tensioner.
8. NOTE: It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
9. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
10. Position the LH secondary timing assembly onto the camshafts.
11. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. 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.
12. Remove the lockpin from the LH secondary timing chain tensioner.
13. Install the crankshaft timing chain sprocket.
14. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
15. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
16. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
17. Install the primary timing chain tensioner arm.
18. 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.
19. 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.
20. As a post-check, verify correct alignment of all timing marks.
21. Inspect the VCT housing seals for damage and replace as necessary.
22. 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).
23. 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).
24. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-372749-S10820801042010093000000) .

Scheme 88

ITEM PART DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
3. Remove the LH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
4. Disconnect the 2 coolant hoses from the oil cooler.
5. NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) . Remove the 6 bolts and the oil cooler. Discard the gaskets. Inspect the oil cooler. Clean and inspect all sealing surfaces.

Scheme 89

1. Using new gaskets, install the oil cooler and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Connect the 2 coolant hoses to the oil cooler.
3. Install the LH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
4. Fill and bleed the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove and discard the engine oil filter.
3. If equipped, remove the engine oil cooler. For additional information, refer to «OIL COOLER»(ref-372749-S08703918132010093000000) .
4. Remove the 3 bolts and the oil filter adapter.

1. Discard the gasket.
2. Clean and inspect all sealing surfaces.

1. Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten to 10 Nm (89 lb-in).
2. If equipped, install the engine oil cooler. For additional information, refer to «OIL COOLER»(ref-372749-S08703918132010093000000) .
3. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 18 Nm (159 lb-in).
4. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.

1. Remove the LH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
2. Remove the LH Heated Oxygen Sensor (HO2S). For additional information, Refer to «ELECTRONIC ENGINE CONTROLS»(ref-372808) .
3. Remove the 3 bolts and the LH exhaust manifold heat shield.
4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
6. Remove and discard the 6 LH exhaust manifold studs.
7. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Scheme 90

1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. 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).
3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
4. Install the LH HO2S . For additional information, Refer to «ELECTRONIC ENGINE CONTROLS»(ref-372808) .
5. Install the LH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .

1. Remove the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
2. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-372759) .
5. Remove and discard the 6 RH exhaust manifold studs.
6. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Scheme 91

1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. 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).
3. Connect the RH HO2S electrical connector.
4. Install the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .

1. Remove the exhaust flexible pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
2. NOTE: The Oil Pan Holding Fixture must be carefully aligned to the mounting bosses on the oil pan. Failure to follow this instruction may result in damage to the oil pan. Position a floor jack and the Oil Pan Holding Fixture under the oil pan.
3. Remove the engine coolant degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
4. Remove the nut, bolt and engine mount brace.
5. Remove the 4 engine mount nuts.
6. NOTE: Only use hand tools to remove the studs. Remove the 4 engine mount studs.
7. Remove the 3 bolts and the engine mount.

1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
2. Install the engine mount and the 3 bolts. Do not tighten the bolts at this time.
3. 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 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 4 engine mount studs. Tighten to 20 Nm (177 lb-in).
4. Tighten the 3 engine mount bolts to 90 Nm (66 lb-ft).
5. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
6. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
7. Install the engine coolant degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
8. Install the exhaust flexible pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .

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

Scheme 92

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-372749-S10820801042010093000000) . Engines equipped with early build RH timing chain guides
2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
3. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
4. 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.
5. 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.
6. Remove the 3 bolts and the RH VCT housing.
7. Remove the 3 bolts and the LH VCT housing.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
14. Remove the 3 bolts and the oil pump.

Scheme 93

1. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
2. 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).
3. Install the crankshaft timing chain sprocket.
4. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
5. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Install the primary timing chain tensioner arm.
7. 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.
8. 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.
9. As a post-check, verify correct alignment of all timing marks.
10. Inspect the VCT housing seals for damage and replace as necessary.
11. 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).
12. 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).
13. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-372749-S10820801042010093000000) .

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.

All camshafts

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Recover the A/C system. For additional information, Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .
3. Remove the cowl panel grille. For additional information, Refer to «FRONT END BODY PANELS»(ref-372798) .
4. Detach the brake booster vacuum hose retainer from the strut tower brace.
5. Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
6. Release the fuel system pressure. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
7. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
8. Remove the battery tray. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
9. Disconnect the engine wiring harness electrical connector.
10. Remove the nut and disconnect the 2 power feed wires from the positive battery terminal.
11. Remove the nut and disconnect the ground cable from the negative battery terminal.
12. Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
13. Remove the LF wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
14. Remove the accessory drive belt and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .
15. Remove the 3 pin-type retainers, 7 bolts and the front valance.
16. Disconnect the power steering cooler tube located at the left front subframe and drain the power steering fluid into a suitable container.
17. Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
18. Remove the nut and the A/C tube. Discard the O-ring seal and gasket seal.
19. Remove the degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
20. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
21. Detach the EVAP tube pin-type retainer from the upper intake manifold.
22. Remove the EVAP canister purge valve. For additional information, Refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
23. Disconnect the PCM and engine harness electrical connectors. Detach the wiring harness retainer.
24. Disconnect the 2 PCM electrical connectors.
25. Remove the engine wiring harness retainer from the bulkhead. Push the wiring harness retainer tab in. Slide the wiring harness up and out of the bulkhead.
26. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
27. Disconnect the transaxle control cable from the control lever.
28. Disconnect the transaxle control cable from the shift cable bracket and detach the wiring harness pin-type retainer.
29. If equipped, detach the engine block heater harness from the radiator support.
30. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
31. Disconnect the fuel supply tube from the fuel rail. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
32. Detach the engine wiring harness retainer.
33. Detach the wire harness retainer from the RH valve cover stud bolt.
34. Remove the bolt and the ground cable from the engine.
35. Disconnect the hose from the power steering reservoir.
36. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position.
37. NOTE: Apply the brake to keep the halfshafts from rotating. NOTE: RH shown in illustration, LH similar. Remove the RH and LH halfshaft nuts. Do not discard at this time.
38. NOTE: RH shown in illustration, LH similar. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
39. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
40. Remove the bolt from the RH brake hose bracket.
41. 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: Index-mark the steering column shaft position to the steering gear for reference during installation. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
42. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
43. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts. All-Wheel Drive (AWD) vehicles
44. NOTE: Index-mark the driveshaft for installation. Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire. All camshafts
45. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
46. Remove and discard the engine oil filter.
47. If equipped, detach the oil cooler hose support clip from the subframe.
48. Remove the Power Steering Pressure (PSP) tube bracket-to-steering gear bolt.
49. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
50. Remove the 2 rear engine roll restrictor-to-transaxle bolts.
51. Remove the 2 front engine roll restrictor-to-transaxle bolts.
52. NOTE: RH shown in illustration, LH similar. Remove and discard the upper stabilizer link nuts.
53. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nuts. NOTE: RH shown in illustration, LH similar. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
54. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or Constant Velocity (CV) boot may occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the lower ball joints from the wheel knuckles.
55. Position the Powertrain Lift under the subframe assembly.
56. NOTE: RH shown in illustration, LH similar. Remove the subframe bracket-to-body bolts.
57. NOTE: RH shown in illustration, LH similar. Remove the rear subframe bolts and the subframe brackets.
58. NOTE: RH shown in illustration, LH similar. Remove the front subframe bolts.
59. Lower the subframe assembly from the vehicle.
60. Pull the RH wheel knuckle outward and rotate it toward the rear of the vehicle. Secure the RH wheel knuckle assembly.
61. Remove the 2 intermediate shaft bracket nuts.
62. Remove the intermediate and halfshaft assembly.
63. NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
64. Remove and discard the circlip from the stub shaft.
65. If equipped, detach the oil cooler coolant hoses.
66. Remove the 2 RH halfshaft support bracket studs.
67. Remove the 4 bolts and the RH halfshaft support bracket.
68. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
69. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
70. NOTE: Position a block of wood under the transaxle. Install the Powertrain Lift and Universal Adapter Brackets.
71. Remove the transaxle mount through bolt and nut.
72. Remove the bolt, 3 nuts and the transaxle mount bracket.
73. Remove the nut, bolt and engine mount brace.
74. Remove the 4 engine mount nuts.
75. Remove the 3 bolts and the engine mount.
76. Lower the engine and transaxle assembly from the vehicle.
77. Disconnect the PCV hose from the PCV valve.
78. Disconnect the Throttle Body (TB) electrical connector.
79. Detach the wiring harness retainers from the upper intake manifold.
80. Remove the upper intake manifold support bracket bolt.
81. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
82. 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.
83. Disconnect the RH catalyst monitor electrical connector.
84. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
85. Disconnect the 3 RH coil-on-plug electrical connectors.
86. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
87. Disconnect the LH VCT solenoid electrical connector.
88. Disconnect the 3 LH coil-on-plug electrical connectors.
89. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
90. NOTE: LH shown in illustration, RH similar. Remove the 6 bolts and the 6 coil-on-plug assemblies.
91. Disconnect the PSP switch electrical connector.
92. Remove the PSP tube bracket-to-power steering pump bolt.
93. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
94. Remove the 3 bolts and position aside the power steering pump.
95. Remove the 3 bolts and the accessory drive belt tensioner. Early build vehicles
96. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
97. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
98. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
99. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
100. 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. Install new seals if damaged. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
101. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
102. Using the 3 Jaw Puller, remove the crankshaft pulley.
103. Using the Oil Seal Remover, remove and discard the crankshaft pulley front seal.
104. Remove the 2 bolts and the engine mount bracket.
105. NOTE: Only use hand tools to remove the studs. Remove the 2 engine mount studs.
106. Remove the 3 bolts and the engine mount bracket.
107. Remove the 22 engine front cover bolts.
108. 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.
109. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. 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 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 to remove any foreign material, including any abrasive particles created during the cleaning process.
110. 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, including any sealant from the inner surface of the cylinder block and cylinder head. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan 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. Engines equipped with early build RH timing chain guides
111. 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
112. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
113. 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.
114. 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.
115. Remove the 3 bolts and the RH VCT housing.
116. Remove the 3 bolts and the LH VCT housing.
117. Remove the 2 bolts and the primary timing chain tensioner.
118. Remove the primary timing chain tensioner arm.
119. Remove the 2 bolts and the lower LH primary timing chain guide.
120. Remove the primary timing chain. LH camshafts
121. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
122. 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 LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
123. 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.
124. 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.
125. 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. RH camshafts
126. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
127. 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.
128. Remove the Camshaft Holding Tool from the RH camshafts.
129. 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.
130. 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.

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.

All camshafts

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

1. 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. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position. LH camshafts
2. NOTE: The camshafts must remain in the neutral position during removal 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.
3. 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). RH camshafts
4. NOTE: The camshafts must remain in the neutral position during removal 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.
5. 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). All camshafts
6. 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. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet (s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-372749-S23648534222010093000000) . LH camshafts
7. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.
8. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
9. Position the LH secondary timing assembly onto the camshafts.
10. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. 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.
11. Remove the lockpin from the LH secondary timing chain tensioner. RH camshafts
12. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.
13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
14. Position the RH secondary timing assembly onto the camshafts.
15. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. 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.
16. Remove the lockpin from the RH secondary timing chain tensioner. All camshafts
17. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Install the primary timing chain tensioner arm.
21. 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.
22. 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.
23. As a post-check, verify correct alignment of all timing marks.
24. Inspect the VCT housing seals for damage and replace as necessary.
25. 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).
26. 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).
27. Install the Alignment Pins.
28. 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 tighten 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.
29. 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).
30. Remove the Alignment Pins.
31. NOTE: Do not tighten the bolts at this time. Install the engine mount bracket and the 3 bolts.
32. 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).
33. 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).
34. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
35. 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.
36. 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.
37. 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.
38. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
39. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
40. 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 seal solenoid installation similar. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
41. 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
42. 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
43. 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
44. 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
45. 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
46. 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
47. Install the PSP tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
48. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
49. Connect the PSP switch electrical connector.
50. 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).
51. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
52. Connect the 3 LH coil-on-plug electrical connectors.
53. Connect the LH VCT solenoid electrical connector.
54. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
55. Connect the 3 RH coil-on-plug electrical connectors.
56. Connect the RH VCT solenoid electrical connector.
57. Connect the RH CMS electrical connector.
58. 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).
59. 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).
60. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
61. Attach the wiring harness retainers to the upper intake manifold.
62. Connect the Throttle Body (TB) electrical connector.
63. Connect the PCV hose to the PCV valve.
64. Raise the engine and transaxle assembly into the vehicle.
65. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
66. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
67. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (177 lb-in).
68. 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).
69. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft). All-Wheel Drive (AWD) vehicles
70. NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-372778) . All camshafts
71. Connect the transaxle cooler tubes and install the 2 secondary latches.
72. 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).
73. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
74. If equipped, connect the oil cooler coolant hoses.
75. 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.
76. 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.
77. Rotate the LH wheel knuckle into position and insert the LH halfshaft into the wheel hub.
78. Install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
79. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
80. Using the Powertrain Lift, raise the subframe into the installed position.
81. NOTE: RH shown in illustration, LH similar. Install the 2 front subframe bolts. Tighten to 200 Nm (148 lb-ft).
82. NOTE: RH shown in illustration, LH similar. Position the subframe brackets and install the 4 bolts finger-tight.
83. NOTE: RH shown in illustration, LH similar. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
84. NOTE: RH shown in illustration, LH similar. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
85. 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).
86. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nuts. NOTE: RH shown in illustration, LH similar. Install new tie-rod end nuts. Tighten to 150 Nm (111 lb-ft).
87. NOTE: RH shown in illustration, LH similar. Install new upper stabilizer bar link nuts. Tighten to 150 Nm (111 lb-ft).
88. Install the 2 front engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
89. Install the 2 rear engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
90. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
91. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
92. If equipped, attach the oil cooler hose support clip to the subframe.
93. 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
94. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown in illustration). Tighten to 70 Nm (52 lb-ft). All camshafts
95. 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.
96. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
97. 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).
98. Position the RH brake hose bracket and install the bolt. Tighten to 30 Nm (22 lb-ft).
99. Position the rubber shield and install the 2 lower scrivets.
100. 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.
101. 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).
102. Connect the hose to the power steering reservoir.
103. Install the oil level indicator.
104. Install the ground cable and bolt. Tighten to 12 Nm (106 lb-in).
105. Attach the wire harness retainer to the RH valve cover stud bolt.
106. Attach the engine wiring harness retainer.
107. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
108. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (133 lb-in).
109. If equipped, attach the block heater wiring harness retainer to the radiator and power steering tube.
110. Connect the transaxle control cable to the shift cable bracket.
111. Connect the transaxle control cable to the control lever.
112. Connect the upper radiator hose, lower radiator hose and heater hose to the thermostat housing.
113. 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.
114. Connect the 2 PCM electrical connectors.
115. Connect the PCM and engine harness electrical connectors. Attach the wiring harness retainer.
116. Install the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
117. Attach the EVAP tube pin-type retainer to the upper intake manifold.
118. Connect the vacuum hose and the EVAP tube to the upper intake manifold.
119. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-372804) .
120. Using a new O-ring seal and gasket seal, install the A/C tube and the nut. Tighten to 15 Nm (133 lb-in).
121. 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).
122. Connect the power steering cooler tube.
123. Install the front valance, 3 pin-type retainers and 7 bolts.
124. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-372765) .
125. Install the LF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-372756) .
126. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
127. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
128. Connect the engine wiring harness electrical connector.
129. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
130. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
131. Install the strut tower brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
132. Attach the brake booster vacuum hose retainers to the strut tower brace.
133. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-372798) .
134. 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. Fill the engine with clean engine oil.
135. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-372804) .
136. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS)»(ref-372763) .
137. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .