Engine Mechanical - 3.7L: Other Ford Mustang V рестайлинг

Engine Code Information Label

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

Scheme 476

ENGINE CODE INFORMATION LABEL REFERENCE 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 article.

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.

Twin Independent Variable Camshaft Timing (VCT) System

The twin independent VCT system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved 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 ensure 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.

Scheme 478

ENGINE ASSEMBLY OIL FLOW REFERENCE CHART

Dual Mass Flywheel

Note. The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

A dual-mass flywheel is essentially two flywheels in one that provides spring cushioning to dampen torsional crankshaft vibrations and shock loading when the clutch is engaged. The two-piece assembly has a front "primary" mass and a rear "secondary" mass. The primary mass bolts to the crankshaft like an ordinary solid flywheel, and includes the ring gear for the starter. The clutch is bolted to the secondary mass, which is separate from the primary mass, but attached to it with a series of coil springs mounted sideways between the two. The springs allow just enough movement between the masses to transmit less engine vibration to the driveline, reduce some of the jarring and stress on the transmission and the remainder of the drivetrain when the clutch is engaged. The cushioning effect also reduces shock loading on the transmission for longer gear life and less noise.

Cooling System

The engine cooling system includes the following

1. Radiator
2. 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

Scheme 479

The channel cover plate is located under the engine front cover mounted to the block. It contains a timing chain idler and press and place gaskets separating engine coolant and engine oil. If oil or coolant is leaking from the weep hole, then a gasket has failed and must be replaced. A weep hole is provided on the front left side of the engine behind the generator. This weep hole create a reservoir for normal coolant seepage and evaporation. Every channel cover plate will have some leakage past the dynamic mechanical seal. Dampness and crusting around the weep hole is acceptable and an expected result of normal engine operation. Coolant spray or leakage amounts great enough to puddle should be addressed.

For basic engine mechanical concerns, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the INTRODUCTION article.

Valve Clearance Check

1. Remove the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-439770-S10010638222011120900000) and «VALVE COVER - RH»(ref-439770-S39369329162011120900000) in this service information.
2. 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. 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-439770-S09904972442011120900000) in this service information.

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UPPER INTAKE MANIFOLD REFERENCE CHART

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UPPER INTAKE MANIFOLD REFERENCE CHART

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1. If equipped, remove the 4 nuts (2 shown in illustration) and the strut tower cross brace.
2. If equipped, detach the 2 retainers and remove the engine appearance cover.
3. Remove the Air Cleaner (ACL) outlet tube. For additional information, refer to Intake Air System Components - Exploded View, 3.7L in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
4. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
5. Disconnect the Throttle Body (TB) electrical connector. Detach the TB electrical connector wiring harness pin-type retainer from the TB .
6. Disconnect Evaporative Emission (EVAP) tube from the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article. Detach the EVAP hose retainer from the intake manifold.
7. Disconnect the EVAP canister purge valve electrical connector. Detach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
8. Disconnect the brake booster vacuum hose from the upper intake manifold vacuum tube.
9. Detach the wiring harness pin-type retainer from the rear of the upper intake manifold.
10. Remove the upper intake manifold support bracket bolt from the front of the RH cylinder head.
11. Loosen the 7 bolts and remove the upper intake manifold.

1. Remove and discard the gaskets.
2. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

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1. Using new gaskets, install the upper intake manifold and tighten the 7 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
2. Install the upper intake manifold support bracket bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
3. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
4. Connect the brake booster vacuum hose to the upper intake manifold vacuum tube.
5. Connect the EVAP canister purge valve electrical connector. Attach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
6. Connect EVAP tube to the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article. Attach the EVAP hose retainer to the intake manifold.
7. Connect the TB electrical connector. Attach the TB electrical connector wiring harness pin-type retainer to the TB .
8. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
9. Install the ACL outlet tube. For additional information, refer to Intake Air System Components - Exploded View, 3.7L in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
10. If equipped, install the engine appearance cover.
11. If equipped, install the strut tower cross brace and the 4 nuts (2 shown in illustration).

1. Tighten to 35 Nm (26 lb-ft).

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LOWER INTAKE MANIFOLD REFERENCE CHART

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LOWER INTAKE MANIFOLD REFERENCE CHART

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LOWER INTAKE MANIFOLD REFERENCE CHART

Material

MATERIAL SPECIFICATIONS

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VALVE COVER REFERENCE CHART

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VALVE COVER REFERENCE CHART

MATERIAL SPECIFICATIONS

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VALVE COVER REFERENCE CHART

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VALVE COVER REFERENCE CHART

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-439777) article.
2. Remove the accessory drive belt and the A/C belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
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.

1. Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the crankshaft front seal lip, replace the crankshaft pulley if necessary.

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1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. 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 A/C belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
5. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Note. Engine Front Cover (View 1 of 2)

Scheme 495

ENGINE FRONT COVER REFERENCE CHART

Note. Engine Front Cover (View 2 of 2)

Scheme 496

ENGINE FRONT COVER REFERENCE CHART

Valve Train Components - Exploded View

Note. LH shown in illustration, RH similar.

Scheme 497

VALVE TRAIN COMPONENTS REFERENCE CHART

1. Refer to the appropriate procedures and/or exploded views in this service information for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

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CYLINDER HEAD REFERENCE CHART

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CYLINDER HEAD REFERENCE CHART

MATERIAL SPECIFICATIONS

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CYLINDER HEAD REFERENCE CHART

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CYLINDER HEAD REFERENCE CHART

MATERIAL SPECIFICATIONS

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EXHAUST MANIFOLD REFERENCE CHART

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EXHAUST MANIFOLD REFERENCE CHART

MATERIAL SPECIFICATIONS

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EXHAUST MANIFOLD REFERENCE CHART

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EXHAUST MANIFOLD REFERENCE CHART

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Note. The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

Scheme 506

DUAL MASS FLYWHEEL REFERENCE

1. Refer to the appropriate procedures and/or exploded views in this service information for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

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CRANKSHAFT REAR SEAL WITH RETAINER PLATE REFERENCE CHART

MATERIAL SPECIFICATIONS

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. For additional information, refer to the exploded view under the ASSEMBLY procedure in this service information.

Engines with automatic transmission

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1. Remove the 8 bolts and the flexplate. Engines with manual transmission
2. Remove the 6 pressure plate bolts, remove the pressure plate and the clutch disc. Discard the pressure plate bolts.
3. Remove the 8 bolts and the dual mass flywheel. All engines
4. Remove the spacer plate.
5. Remove the crankshaft sensor ring.
6. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
7. Using the Floor Crane and Spreader Bar, mount the engine on a suitable engine stand.
8. Remove the LH and RH engine lift eyes.
9. Remove the crankcase vent tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
10. Remove the engine oil level indicator.
11. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector. Detach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
12. Disconnect the Throttle Body (TB) electrical connector. Detach the TB electrical connector wiring harness pin-type retainer from the TB .
13. Disconnect the PCV tube quick connect couplings from the PCV valve and intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
14. Detach the wiring harness pin-type retainer from the rear of the upper intake manifold.
15. Remove the LH fuel rail insulator.
16. Remove the upper intake manifold support bracket bolt from the front of the RH cylinder head.
17. Loosen the 7 bolts and remove the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
18. Remove the RH fuel rail insulator.
19. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
20. Disconnect the Cylinder Head Temperature (CHT) sensor wiring harness jumper electrical connector.
21. Disconnect the 3 RH fuel rail electrical connectors.
22. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
23. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
24. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. Detach the EOP switch wiring harness retainer from the cylinder head.
26. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
27. Disconnect the 3 LH fuel rail electrical connectors.
28. Disconnect the 2 LH VCT solenoid electrical connectors.
29. Disconnect the Knock Sensor (KS) sensor electrical connector.
30. Disconnect the 2 LH CMP sensors electrical connectors. Detach the wiring harness retainer from the rear of the cylinder head.
31. Remove the nut, the bolt and the heat shield.
32. Remove the wiring harness retainer stud bolt.
33. Remove the wiring harness grommet.
34. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
35. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
36. Remove the nut, bolt and the generator. Remove the generator stud.
37. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the crankshaft front seal lip, replace the crankshaft pulley if necessary. 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 accessory drive belt tensioner.
41. Remove the LH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
42. Remove the RH cylinder block drain plug. Allow coolant to drain from the cylinder block.
43. Remove the heater tube bolt.
44. Detach the heater tube retainer from the RH valve cover stud bolt.
45. Remove the 4 bolts and the thermostat housing. Discard the thermostat housing and coolant inlet tube O-ring seals.
46. Remove the 4 bolts and the coolant pump pulley.
47. Remove the 7 bolts and the coolant pump. Discard the coolant pump gasket and coolant pump O-ring seal.
48. Remove the 3 bolts and the 3 LH ignition coil-on-plugs.
49. Remove the 3 LH spark plugs.
50. Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover. Discard the gasket.
51. Inspect the 2 VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
52. Inspect the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
53. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
54. Remove the 2 bolts and the LH exhaust manifold heat shield.
55. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
56. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
57. Remove and discard the 6 LH exhaust manifold studs.
58. Remove the 3 bolts and the 3 RH ignition coil-on-plugs.
59. Remove the 3 RH spark plugs.
60. Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover. Discard the gasket.
61. Inspect the 2 VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
62. Inspect the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
63. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
64. Remove the 2 bolts and the RH exhaust manifold heat shield.
65. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
66. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
67. Remove and discard the 6 RH exhaust manifold studs.
68. Remove the 2 bolts and the LH CMP sensors.
69. Remove the 2 bolts and the RH CMP sensors.
70. Remove the bolt and the CKP sensor.
71. Remove the 5 bolts and the oil filter adapter. Discard the gasket.
72. Remove the 22 engine front cover bolts.
73. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
74. Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.
75. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.
76. Remove the 3 bolts and the LH valve train oil tube.
77. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
78. Remove the 3 bolts and the RH valve train oil tube.
79. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
80. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
81. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
82. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
83. Remove the 2 bolts and the primary timing chain tensioner.
84. Remove the primary timing chain tensioner arm.
85. Remove the 2 bolts and the lower LH primary timing chain guide.
86. Remove the bolt and the LH intake VCT oil control solenoid.
87. Remove the bolt and the RH intake VCT oil control solenoid.
88. Remove the primary timing chain.
89. Remove the crankshaft timing chain sprocket.
90. Remove the bolt and the upper LH primary timing chain guide.
91. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
92. Remove and discard the 2 LH VCT assembly bolts.
93. Remove the 2 LH VCT assemblies and secondary timing chain.
94. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
95. Remove and discard the 2 RH VCT assembly bolts.
96. Remove the 2 RH VCT assemblies and secondary timing chain.
97. Remove the bolt and the RH primary timing chain guide.
98. Remove the 9 bolts and the channel cover plate. Discard the gasket.
99. Remove the Camshaft Holding Tool from the LH camshafts.
100. Verify the LH camshafts are in the neutral position.
101. Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.
102. Remove the Camshaft Holding Tool from the RH camshafts.
103. Rotate the RH camshafts counterclockwise to the neutral position.
104. Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.
105. Remove the valve tappets from the cylinder heads.
106. Inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
107. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
108. Disconnect and remove the CHT sensor jumper harness.
109. Remove and discard the M6 bolt from each cylinder head.
110. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
111. 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.
112. 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 MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
113. Remove the 2 bolts and the KS .
114. Remove the 16 oil pan bolts.
115. Using a suitable pry tool, locate the 2 pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.
116. Remove the 3 bolts and the oil pump screen and the pickup tube. Discard the O-ring seal.
117. Remove the 3 bolts and the oil pump.
118. Remove the 8 crankshaft rear seal retainer bolts.
119. 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.
120. 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.
121. 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.
122. Remove the bolts in the sequence shown in illustration. Remove the main bearing cap support brace. Discard the bolts.
123. Remove the connecting rod cap bolts and cap.
124. Remove the piston/rod assembly from the engine block.
125. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
126. Remove the 8 main bearing cap side bolts in the sequence shown in illustration. Discard the bolts.
127. Remove the 8 main bearing cap bolts in the sequence shown in illustration. Discard the bolts.
128. Remove the 4 main bearing caps.
129. Remove the crankshaft.
130. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
131. Remove the 4 crankshaft main bearings from the cylinder block.
132. Remove the 4 crankshaft main bearings from the main bearing caps.
133. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
134. 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 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.
135. 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.

1. 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.

MATERIAL SPECIFICATIONS

Note. RH cylinder head shown in illustration, LH cylinder head similar.

Scheme 586

CYLINDER HEAD REFERENCE CHART

MATERIAL SPECIFICATIONS

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PISTON REFERENCE CHART

MATERIAL SPECIFICATIONS

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ENGINE UPPER REFERENCE CHART

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ENGINE UPPER REFERENCE CHART

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ENGINE UPPER REFERENCE CHART

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ENGINE FRONT REFERENCE CHART

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LOWER ENGINE BLOCK REFERENCE CHART

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LOWER ENGINE BLOCK REFERENCE 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. 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 MECHANICAL SYSTEM - GENERAL INFORMATION article.

Note. Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G 372 BA or 1G 373 CA) and late build engines are built with engine code (1G 372 CA or 1G 373 DA).

All engines

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Scheme 710

1. 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. 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. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
8. Install the crankshaft onto the upper main bearings.
9. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
10. 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. 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. Early built engines NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G 372 BA or 1G 373 CA) and late build engines are built with engine code (1G 372 CA or 1G 373 DA).
16. 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. Late built engines NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G 372 BA or 1G 373 CA) and late build engines are built with engine code (1G 372 CA or 1G 373 DA) .
18. Tighten the main bearing bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
19. 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 24 Nm (18 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees. All engines
20. 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.
21. 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.
22. 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
23. Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
24. Seat the connecting rod on the crankshaft journal.
25. 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.
26. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
27. 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.
28. 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.
29. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
30. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
31. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
32. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan-to-engine block mating surface.
33. 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.
34. Install the oil pan and bolts 10, 11, 13 and 14 finger tight.
35. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
36. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration to 3 Nm (27 lb-in).
37. Install the remaining oil pan bolts and tighten in the sequence shown in illustration. Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees. Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees. Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
38. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
39. 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 45 degrees.
40. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
41. 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 45 degrees.
42. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
43. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
44. Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
45. Install the valve tappets.
46. Position the crankshaft dowel pin in the 9 o'clock position.
47. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
48. Position the 4 camshaft seals gaps as shown in illustration.
49. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
50. Loosen the 4 camshaft caps bolts.
51. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
52. 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-439770-S10755681692011120900000) in this service information.
53. Remove the 3 bolts and the RH valve train oil tube.
54. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown in illustration.
55. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
56. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
57. Position the 4 camshaft seals gaps as shown in illustration.
58. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
59. Loosen the 4 camshaft caps bolts.
60. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
61. 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-439770-S10755681692011120900000) in this service information.
62. Remove the 3 bolts and the LH valve train oil tube.
63. Rotate the LH camshafts to the TDC position as shown in illustration.
64. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
65. Using a new gasket, install the timing chain gear and the 9 bolts. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
66. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in). Engines with secondary timing chain tensioner removed NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
67. Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
68. Install the RH secondary timing chain tensioner shoe.
69. Remove and discard the RH secondary timing chain tensioner shipping clip.
70. 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.
71. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
72. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
73. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
74. Install the RH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
75. Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
76. Install the LH secondary timing chain tensioner shoe.
77. Remove and discard the LH secondary timing chain tensioner shipping clip.
78. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
79. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
80. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
81. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
82. Install the LH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees. Engines with secondary timing chain tensioner not removed
83. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
84. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
85. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
86. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
87. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
88. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
89. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
90. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
91. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
92. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides. All engines
93. Install the upper LH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
94. Rotate the crankshaft clockwise to the TDC position (crankshaft dowel pin at 11 o'clock).
95. Install the crankshaft timing chain sprocket with timing dot mark out.
96. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
97. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
98. Install the primary timing chain tensioner arm.
99. Reset the primary timing chain tensioner. Release the ratchet detent. Using a soft-jawed vise, compress the ratchet plunger. Align the hole in the ratchet plunger with the hole in the tensioner housing. Install a suitable lockpin.
100. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
101. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
102. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
103. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
104. Remove the RH Camshaft Holding Tool.
105. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
106. Remove the LH Camshaft Holding Tool.
107. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
108. Using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.
109. 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 2 engine front cover bolt 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.
110. Install the engine front cover and bolts 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21. Tighten in sequence to 3 Nm (27 lb-in).
111. Install the remaining 18 engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration in 4 stages: Stage 1: Tighten bolts 1 through 21 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 1 through 20 to 24 Nm (18 lb-ft). Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees. Stage 4: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
112. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown in illustration. Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.
113. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
114. Install the 2 RH Camshaft Position (CMP) sensors and the bolts. Tighten to 10 Nm (89 lb-in).
115. Install the 2 LH CMP sensors and the bolts. Tighten to 10 Nm (89 lb-in).
116. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
117. 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 19 Nm (168 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
118. Install the RH exhaust manifold heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
119. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
120. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
121. 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.
122. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
123. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
124. Install the 3 RH spark plugs. Tighten to 15 Nm (133 lb-in).
125. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals. To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
126. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
127. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
128. 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 19 Nm (168 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
129. Install the LH exhaust manifold heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
130. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
131. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
132. 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.
133. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
134. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
135. Install the 3 LH spark plugs. Tighten to 15 Nm (133 lb-in).
136. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals. To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
137. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
138. Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
139. Install the coolant pump pulley and the 4 bolts. Tighten to 24 Nm (18 lb-ft).
140. Install the thermostat housing and the 4 bolts and tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
141. Attach the heater tube retainer to the RH valve cover stud bolt.
142. Install the heater tube bolt. Tighten to 23 Nm (17 lb-ft).
143. Install the RH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
144. Install the LH cylinder block drain plug or, if equipped, the block heater. Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees. Tighten the block heater to 40 Nm (30 lb-ft).
145. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
146. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
147. Lubricate the crankshaft front seal inner lip with clean engine oil.
148. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.
149. 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.
150. Install the generator stud and position the generator and install the nut and bolt. Tighten the stud to 8 Nm (71 lb-in). Tighten the nut and bolt to 48 Nm (35 lb-ft).
151. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
152. Connect the CKP sensor electrical connector.
153. Install the wiring harness grommet.
154. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
155. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
156. Connect the 2 LH CMP sensors electrical connectors. Attach the wiring harness retainer to the rear of the cylinder head.
157. Connect the KS sensor electrical connector.
158. Connect the 2 LH VCT solenoid electrical connectors.
159. Connect the 3 LH fuel rail electrical connectors.
160. Connect the 3 LH ignition coil-on-plug electrical connectors.
161. Connect the Engine Oil Pressure (EOP) switch electrical connector. Attach the EOP switch wiring harness retainer to the cylinder head.
162. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
163. Connect the 2 RH CMP sensors electrical connectors.
164. Connect the 2 RH VCT solenoid electrical connectors.
165. Connect the 3 RH fuel rail electrical connectors.
166. Connect the CHT sensor wiring harness jumper electrical connector.
167. Connect the 3 RH ignition coil-on-plug electrical connectors.
168. Install the RH fuel rail insulator.
169. Using new gaskets, install the upper intake manifold and tighten the 7 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
170. Install the upper intake manifold support bracket bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
171. Install the LH fuel rail insulator.
172. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
173. Connect the PCV tube quick connect couplings to the PCV valve and intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
174. Connect the Throttle Body (TB) electrical connector. Attach the TB electrical connector wiring harness pin-type retainer to the TB .
175. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector. Attach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
176. Install the engine oil level indicator.
177. Install the crankcase vent tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
178. Install the LH engine lift eye.
179. Install the RH front lift eye.
180. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
181. 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.
182. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
183. Install the crankshaft sensor ring.
184. Install the spacer plate. Engines with manual transmission
185. Install the dual mass flywheel and the 8 bolts and tighten is sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).
186. Using a suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 6 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured. Tighten the pressure plate bolts in 2 stages in a star pattern Stage 1: Tighten to 47 Nm (35 lb-ft). Stage 2: Tighten an additional 60 degrees. Engines with automatic transmission
187. Install the flexplate and the 8 bolts and tighten is sequence shown in illustration.

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

Scheme 711

MATERIAL SPECIFICATIONS

Scheme 712

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Scheme 750

1. Lubricate the torque converter pilot hub with multi-purpose grease.
2. Using the Floor Crane and Spreader Bar, position the engine in the engine compartment.
3. Align the engine to the transmission and install LH bellhousing-to-engine bolt. Tighten the bolt, it will be torqued at a later step.
4. Install the engine-to-bellhousing bolt. Tighten the bolt, it will be torqued at a later step.
5. Install the RH engine mount bracket, bolt and 2 stud bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
6. Install the LH engine mount bracket and the 3 bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
7. Install the 4 upper bellhousing-to-engine bolts and stud bolts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
8. Attach the 2 wiring harness retainers (1 shown in illustration) to the upper transmission stud bolts.
9. Install the ground wire and the bolt on the rear of the cylinder head. Tighten to 10 Nm (89 lb-in).
10. Install the oil pan-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
11. Tighten the engine-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
12. Install the 2 LH bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the LH bellhousing-to-engine bolt. Tighten to 48 Nm (35 lb-ft).
14. Tighten LH bellhousing-to-engine bolt. Tighten to 48 Nm (35 lb-ft).
15. Remove the 3 bolts and lower the underbody shield.
16. Position the transmission cooler tubes clamp on the RH engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
17. Position the wiring harness retainer on the RH rear engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
18. Install the new 2 LH and RH catalytic convertor-to-exhaust manifold nuts. Tighten to 45 Nm (35 lb-ft).
19. Install the 4 torque converter nuts. Tighten to 44 Nm (32 lb-ft).
20. Install the access cover and the 2 pin-type retainers.
21. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
22. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
23. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
24. Raise the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
25. Position the A/C compressor and install the bolt and stud bolt. Do not torque at this time.
26. Install the A/C compressor stud and nut. Tighten the stud to 9 Nm (80 lb-in). Tighten the nut to 26 Nm (19 lb-ft).
27. Tighten the A/C compressor bolt and stud bolt. Tighten the nut to 26 Nm (19 lb-ft).
28. Attach the wiring harness retainer to the A/C compressor stud bolt.
29. If equipped, connect the block heater electrical connector.
30. Install the wiring harness bracket on the LH valve cover stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
31. Connect the generator electrical connector. Attach the generator wiring harness retainer to the valve cover and valve cover stud bolt.
32. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
33. Connect and attach the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.
34. Connect the 2 heater hose couplings (1 shown in illustration) at the RH rear of the engine. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
35. Connect the middle PCM electrical connector. Attach the PCM wiring harness pin-type retainer.
36. Connect the engine wiring harness electrical connector. Attach the wiring harness pin-type retainer to the bracket.
37. Connect the brake booster vacuum hose to the engine.
38. Attach the fuel supply tube and EVAP tube retainer to the LH valve cover.
39. Position and connect the Evaporative Emission (EVAP) tube to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article. Attach the EVAP tube retainer to the intake manifold.
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
41. Connect the upper and lower radiator hoses to the thermostat housing.
42. Install the RH and LH engine mount bracket-to-engine mount nuts. Tighten to 63 Nm (46 lb-ft).
43. Install the accessory drive belt and A/C compressor belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
44. Install the degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
45. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
46. Lift the cowl screen and install the ground strap and bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
47. Install the 2 LH cowl vent screen plastic rivets.
48. If equipped, install the engine appearance cover.
49. If equipped, install the strut tower cross brace and the 4 nuts (2 shown in illustration). Tighten to 35 Nm (26 lb-ft).
50. Align the hood and install the 4 bolts (2 shown in illustration). Tighten to 12 Nm (106 lb-in).
51. Connect the 2 windshield washer hose C-Lock Couplers and attach the 2 windshield washer hose retainers. For additional information, refer to «WIPER SYSTEM & WASHER SYSTEM»(ref-439820) article.
52. Attach the 2 windshield washer hose retainers and install the 8 hood insulation pin-type retainer (2 shown in illustration).
53. Fill the engine with clean engine oil.
54. Fill the engine cooling system. For additional Information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
55. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-439815) article.
56. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

MATERIAL SPECIFICATIONS

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

1. Using the Floor Crane and Spreader Bar, position the engine in the engine compartment.
2. Align the engine to the transmission and install LH bellhousing-to-oil pan bolt. Tighten the bolt, it will be torqued at a later step.
3. Install the engine-to-bellhousing bolt. Tighten the bolt, it will be torqued at a later step.
4. Install the RH engine mount bracket, bolt and 2 stud bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
5. Install the LH engine mount bracket and the 3 bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
6. Install the 4 upper bellhousing-to-engine bolt and stud bolts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
7. Attach the 2 wiring harness retainers (1 shown in illustration) to the upper transmission stud bolts.
8. Install the ground wire and the bolt on the rear of the cylinder head. Tighten to 10 Nm (89 lb-in).
9. Install the oil pan-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
10. Tighten the engine-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
11. Install the LH bellhousing-to-engine bolt and LH bellhousing-to-oil pan stud bolt. Tighten to 48 Nm (35 lb-ft).
12. Tighten the LH bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
13. Remove the 3 bolts and lower the underbody shield.
14. Position the wiring harness retainer on the RH front engine mount bracket stud bolt.
15. Position the wiring harness retainer on the RH rear engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
16. Install the new 2 LH and RH catalytic convertor-to-exhaust manifold nuts. Tighten to 45 Nm (35 lb-ft).
17. Install the access cover and the 2 pin-type retainers.
18. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
19. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
20. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
21. Raise the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
22. Position the A/C compressor and install the bolt and stud bolt. Do not torque at this time.
23. Install the A/C compressor stud and nut. Tighten the stud to 9 Nm (80 lb-in). Tighten the nut to 26 Nm (19 lb-ft).
24. Tighten the A/C compressor bolt and stud bolt. Tighten the nut to 26 Nm (19 lb-ft).
25. Attach the wiring harness retainer to the A/C compressor stud bolt.
26. If equipped, connect the block heater electrical connector.
27. Install the wiring harness bracket on the LH valve cover stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
28. Connect the generator electrical connector. Attach the generator wiring harness retainer to the valve cover stud bolt.
29. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
30. Connect and attach the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.
31. Connect the 2 heater hose couplings (1 shown in illustration) at the RH rear of the engine. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
32. Connect the middle PCM electrical connector. Attach the PCM wiring harness pin-type retainer.
33. Connect the engine wiring harness electrical connector. Attach the wiring harness pin-type retainer to the bracket.
34. Connect the brake booster vacuum hose to the engine.
35. Attach the fuel supply tube and EVAP tube retainer to the LH valve cover.
36. Position and connect the Evaporative Emission (EVAP) tube to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article. Attach the EVAP tube retainer to the intake manifold.
37. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
38. Connect the upper and lower radiator hoses to the thermostat housing.
39. Install the RH and LH engine mount bracket-to-engine mount nuts. Tighten to 63 Nm (46 lb-ft).
40. Install the accessory drive belt and A/C compressor belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
41. Install the degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
42. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
43. Lift the cowl screen and install the ground strap and bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
44. Install the 2 LH cowl vent screen plastic rivets.
45. If equipped, install the engine appearance cover.
46. If equipped, install the strut tower cross brace and the 4 nuts (2 shown in illustration). Tighten to 35 Nm (26 lb-ft).
47. Align the hood and install the 4 bolts (2 shown in illustration). Tighten to 12 Nm (106 lb-in).
48. Connect the 2 windshield washer hose C-Lock Couplers and attach the 2 windshield washer hose retainers. For additional information, refer to «WIPER SYSTEM & WASHER SYSTEM»(ref-439820) article.
49. Attach the 2 windshield washer hose retainers and install the 8 hood insulation pin-type retainer (2 shown in illustration).
50. Fill the engine with clean engine oil.
51. Fill the engine cooling system. For additional Information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
52. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-439815) article.
53. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.