Engine Mechanical - 5.0L (4V): Specifications Ford Mustang V рестайлинг

Material Specifications

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

The 5.0L (302 CID) is a V-8 engine with the following features

1. Dual overhead camshafts
2. Four valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder heads
5. Aluminum, 90-degree V-cylinder block
6. Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
7. Electronic ignition system with 8 ignition coils

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/mustang/v-2009-2014/remont/hoistjack/#jacking-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-439829) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
5. Remove the RH and LH valve covers. For additional information, refer to «VALVE COVER - RH»(ref-439771-S27984334632011120900000) and «VALVE COVER - LH»(ref-439771-S12319399162011120900000) in this service information.
6. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
7. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
8. Loosen the 4 coolant pump pulley bolts.
9. Remove the accessory drive and A/C compressor belts. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
10. Disconnect the lower radiator hose from the thermostat housing assembly.
11. Remove the 2 thermostat housing bolts.
12. Release the clamp and position the upper radiator hose T-connector/thermostat housing assembly aside. Remove and discard the thermostat housing O-ring seal.
13. Disconnect the heater hose. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
14. Remove the 4 bolts and the coolant pump pulley.
15. Remove the 4 bolts and the coolant pump. Remove and discard the O-ring seal.
16. Disconnect the throttle body and Evaporative Emission (EVAP) purge valve electrical connectors.
17. Detach the 3 wiring harness retainers from the engine front cover and stud bolt.
18. Remove the bolt and the accessory drive belt tensioner.
19. Remove the nut, the bolt and position the generator aside.
20. Remove the crankshaft pulley bolt and washer.
21. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley. Discard the crankshaft pulley bolt.
22. Using the Oil Seal Remover, remove the crankshaft front oil seal.
23. Remove the 3 bolts and lower the underbody shield.
24. Remove the 2 wiring harness retainer nuts from the front oil pan stud bolts.
25. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.
26. Remove the 13 engine front cover bolts and the 2 stud bolts.
27. Remove the engine front cover from the front cover to cylinder block dowel. Remove and discard the engine front cover gaskets. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
28. Drain the engine oil. Install the drain plug and tighten to 26 Nm (19 lb-ft).

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1. Fully depress the VCT variable force solenoid pins.
2. Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.
3. Using new gaskets, position the engine front cover onto the dowels. Install the 13 engine front cover bolts, 2 stud bolts and the 4 oil pan-to-engine front cover bolts finger-tight.
4. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.
5. Position the wiring harness and install the 2 wiring harness retainer nuts to the front oil pan stud bolts.
6. Position the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
7. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.
8. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
9. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
10. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.
11. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages: Stage 1: Tighten to 140 Nm (103 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 100 Nm (74 lb-ft). Stage 4: Tighten an additional 90 degrees.
12. Install the generator, the bolt and the nut. Tighten to 48 Nm (35 lb-ft).
13. Install the accessory drive belt tensioner and bolt. Tighten to 48 Nm (35 lb-ft).
14. Attach the 3 wiring harness retainers to the engine front cover and stud bolt.
15. Connect the throttle body and Evaporative Emission (EVAP) purge valve electrical connectors.
16. Using a new O-ring seal, install the coolant pump and the 4 bolts. Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.
17. Install the coolant pump pulley and the 4 bolts.
18. Connect the heater hose. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
19. Using a new thermostat housing O-ring seal, install the upper radiator hose T-connector/thermostat housing assembly.
20. Install the 2 thermostat housing bolts. Tighten to 10 Nm (89 lb-in).
21. Connect the lower radiator hose to the thermostat housing assembly.
22. Install the accessory drive and A/C compressor belts. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
23. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).
24. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
25. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
26. Install the RH and LH valve covers. For additional information, refer to «VALVE COVER - RH»(ref-439771-S27984334632011120900000) and «VALVE COVER - LH»(ref-439771-S12319399162011120900000) in this service information.
27. Fill the crankcase with clean engine oil.
28. Connect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-439815) article.
29. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
30. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/mustang/v-2009-2014/remont/hoistjack/#jacking-lifting) article.
2. Recover the refrigerant. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
3. If equipped, remove the 4 nuts and the strut tower cross brace.
4. Remove the engine appearance cover.
5. Remove the bolt and position the sound enhancement pipe aside.
6. Remove the 8 pin-type retainers and the upper radiator sight shield.
7. Remove the A/C compressor fitting nut and disconnect the fitting. Discard the O-ring seals and gasket seals.
8. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-439815) article.
9. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
10. Install an Engine Lifting Bracket on the rear of the RH cylinder head.
11. Install the Engine Support Bar.
12. Remove the RH and LH engine support insulator nuts.
13. Using the Engine Support Bar, raise the engine 25 mm (0.984 in).
14. Remove the 4 nuts (2 shown in illustration) and the front crossmember brace.
15. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-439784) article.
16. Remove the starter. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
17. Remove the 3 bolts and lower the underbody shield.
18. Remove the transmission fluid cooler tube nut and bracket from the flexplate inspection cover stud bolt.
19. Remove the nut from the RH engine support insulator bracket stud bolt and position the transmission cooler tube clamp aside.
20. Detach the wiring harness retainers from the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
21. Remove the nut and ground strap from the RH engine support insulator bracket.
22. Remove the 2 bolts, the 2 stud bolts and the RH engine support insulator bracket.
23. Remove the 8 nuts and the RH exhaust manifold. Discard the gasket.
24. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
25. Remove and discard the 8 RH exhaust manifold studs.

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1. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
2. Install 8 new RH exhaust manifold studs. Tighten to 25 Nm (18 lb-ft).
3. Install new gaskets, the RH exhaust manifold and 8 new nuts. Tighten early build (coarse thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 28 Nm (21 lb-ft). Stage 2: Tighten to 37 Nm (27 lb-ft). Tighten late build (fine thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 24 Nm (18 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
4. Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
5. Install the ground strap and the nut to the RH engine support insulator bracket. Tighten to 48 Nm (35 lb-ft).
6. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
7. Install the transmission cooler tube clamp and nut to the RH engine support insulator bracket. Tighten to 48 Nm (35 lb-ft).
8. Install the transmission fluid cooler tube bracket and nut to the flexplate inspection cover stud bolt. Tighten to 13 Nm (115 lb-in).
9. Position the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the starter. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
11. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-439784) article.
12. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
13. Using the Engine Support Bar, lower the engine onto the engine support insulators.
14. Install the RH and LH engine support insulator nuts. Tighten to 63 Nm (46 lb-ft).
15. Connect the RH HO2S electrical connector.
16. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
17. Using a new O-ring seal and gasket seal, connect the A/C compressor fitting and install the nut Tighten to 15 Nm (133 lb-in).
18. Position the sound enhancement pipe and install the bolt. Tighten to 8 Nm (71 lb-in).
19. Install the upper radiator sight shield and the 8 pin-type retainers.
20. Install the engine appearance cover.
21. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
22. Recharge the A/C system. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.

MATERIAL SPECIFICATIONS CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/mustang/v-2009-2014/remont/hoistjack/#jacking-lifting) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
3. Remove the 2 steering column dash boot nuts.
4. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
5. If equipped, remove the 4 nuts and the strut tower cross brace.
6. Remove the engine appearance cover.
7. Disconnect the sound enhancement pipe from the Air Cleaner (ACL) outlet pipe and the ACL . For additional information, refer to the exploded view in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article. Position the sound enhancement pipe aside.
8. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-439784) article.
9. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
10. Remove the bolt and position the steering intermediate shaft aside.
11. Remove the 8 nuts and the LH exhaust manifold. Discard the gasket.
12. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
13. Remove and discard the 8 LH exhaust manifold studs.

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1. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
2. Install 8 new LH exhaust manifold studs. Tighten to 25 Nm (18 lb-ft).
3. Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten early build (coarse thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 28 Nm (21 lb-ft). Stage 2: Tighten to 37 Nm (27 lb-ft). Tighten late build (fine thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 24 Nm (18 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
4. Position the steering intermediate shaft and install the bolt. Tighten to 47 Nm (35 lb-in).
5. Connect the LH HO2S electrical connector.
6. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-439784) article.
7. Connect the sound enhancement pipe to the ACL outlet pipe and the ACL . For additional information, refer to the exploded view in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
8. Install the engine appearance cover.
9. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
10. Install the 2 steering column dash boot nuts. Tighten to 9 Nm (80 lb-in).
11. Connect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-439815) article.

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1. Refer to the 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

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/mustang/v-2009-2014/remont/hoistjack/#jacking-lifting) article.
2. Remove the flywheel or flexplate. For additional information, refer to «FLEXPLATE OR FLYWHEEL AND CRANKSHAFT REAR SEAL - EXPLODED VIEW»(ref-439771-S03704986962011120900000) and «FLEXPLATE»(ref-439771-S35939812372011120900000) or «FLYWHEEL»(ref-439771-S41279787822011120900000) in this service information.
3. Remove the engine separator plate.
4. Remove the crankshaft sensor ring.
5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.

Scheme 854

1. 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 engine separator plate.
5. Install the flywheel or flexplate. For additional information, refer to «FLEXPLATE OR FLYWHEEL AND CRANKSHAFT REAR SEAL - EXPLODED VIEW»(ref-439771-S03704986962011120900000) and «FLEXPLATE»(ref-439771-S35939812372011120900000) or «FLYWHEEL»(ref-439771-S41279787822011120900000) in this service information.

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Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

Note. If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.

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

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1. Remove the engine. For additional information, refer to «ENGINE - MANUAL TRANSMISSION»(ref-439771-S16591063372011120900000) or «ENGINE - AUTOMATIC TRANSMISSION»(ref-439771-S38802972202011120900000) in this service information.
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 flywheel or flexplate. Discard the bolts. Remove the engine separator plate.
4. Remove the crankshaft sensor ring.
5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
6. Mount the engine on a work stand.
7. Disconnect the oil level sensor electrical connector and the 2 wiring harness retainers.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.
9. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors. Remove the 2 bolts and the LH intake and exhaust CMP sensors.
10. Disconnect the 2 Knock Sensor (KS) electrical connectors.
11. Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors. Remove the 2 bolts and the RH intake and exhaust CMP sensors.
12. Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor electrical connectors.
13. Disconnect the 4 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
14. Disconnect the 8 ignition coil electrical connectors.
15. Detach the 9 wiring harness retainers from the RH valve cover and the 10 wiring harness retainers from the LH valve cover.
16. Detach the 2 wiring harness retainers from the engine front cover and stud bolts. Remove the wiring harness from the engine.
17. Remove the 8 bolts and the 8 ignition coils.
18. Loosen the 14 bolts and remove the RH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
19. Remove the oil level indicator.
20. Loosen the 14 bolts and remove the LH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
21. Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
22. Inspect the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
23. Remove the 8 nuts and the RH exhaust manifold. Discard the gasket.
24. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
25. Remove and discard the 8 RH exhaust manifold studs.
26. Remove the 8 nuts and the LH exhaust manifold. Discard the gasket.
27. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
28. Remove and discard the 8 LH exhaust manifold studs.
29. Remove the 4 bolts and the coolant pump pulley.
30. Remove the 4 bolts and the coolant pump. Remove and discard the O-ring seal.
31. Remove the bolt and the accessory drive belt tensioner.
32. Remove the nut, the bolt and the generator.
33. Remove the crankshaft pulley bolt and washer.
34. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley. Discard the crankshaft pulley bolt.
35. Using the Oil Seal Remover, remove the crankshaft front oil seal.
36. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.
37. Remove the 13 engine front cover bolts and the 2 stud bolts.
38. Remove the engine front cover from the front cover to cylinder block dowel. Remove and discard the engine front cover gaskets. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
39. Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.
40. Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one revolution.
41. Remove the 2 bolts and the RH primary timing chain tensioner.
42. Remove the RH timing chain tensioner arm.
43. Remove the bolt and the RH timing chain guide.
44. Remove the RH primary timing chain.
45. Remove the 3 RH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 RH exhaust VCT assembly bolts.
46. Slide the RH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
47. Depress the RH secondary timing chain tensioner and turn the tensioner 90 degrees.
48. Remove the RH VCT assemblies and the RH secondary timing chain.
49. Remove the 4 bolts and the RH front camshaft bearing mega cap.
50. Remove the 16 bolts and the 8 camshaft bearing caps.
51. Remove the VCT system oil filter from the intake and exhaust camshafts.
52. Remove the RH intake and exhaust camshafts.
53. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
54. Remove the bolt and the coolant outlet pipe from the RH cylinder head. Remove and discard the O-ring seal.
55. Remove the CHT sensor.
56. Remove the 10 bolts and the RH cylinder head. Discard the bolts and the cylinder head gasket.
57. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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.
58. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
59. Using the crankshaft holding tool, rotate the crankshaft counterclockwise until the crankshaft keyway is at the 9 o'clock position.
60. Remove the 2 bolts and the LH primary timing chain tensioner.
61. Remove the LH timing chain tensioner arm.
62. Remove the bolt and the LH timing chain guide.
63. Remove the LH primary timing chain.
64. Remove the crankshaft sprocket.
65. Remove the 3 LH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 LH exhaust VCT assembly bolts.
66. Slide the LH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
67. Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.
68. Remove the LH VCT assemblies and the LH secondary timing chain.
69. Remove the 4 bolts and the LH front camshaft bearing mega cap.
70. Remove the 16 bolts and the 8 camshaft bearing caps.
71. Remove the VCT system oil filter from the intake and exhaust camshafts.
72. Remove the LH intake and exhaust camshafts.
73. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
74. Remove the 2 bolts and the coolant outlet from the LH cylinder head. Remove and discard the gasket.
75. Remove the 10 bolts and the LH cylinder head. Discard the bolts and the cylinder head gasket.
76. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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.
77. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
78. Remove the 2 bolts and the 2 KS .
79. Remove the bolt and the Crankshaft Position (CKP) sensor.
80. Remove and discard the oil filter.
81. Remove the 3 bolts and the oil filter adapter. Discard the gasket.
82. Remove the bolts and the oil pan. Clean and inspect the sealing surface.
83. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
84. Remove the oil pump screen and pickup tube spacer.
85. Remove and discard the oil pan baffle and gasket.
86. Remove the 6 bolts and the crankshaft rear seal retainer plate. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean and inspect the sealing surfaces.
87. Remove the 2 bolts, the 2 stud bolts and the oil pump.
88. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
89. Remove the bolts and the connecting rod cap. Discard the bolts.
90. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
91. Repeat the previous 2 steps for each of the remaining pistons.
92. Disassemble the 8 pistons. For additional information, refer to «PISTON»(ref-439771-S26536399552011120900000) in this service information.
93. Remove the fasteners. Remove and discard the cross-mounted main cap bolts. Remove and discard the main bearing cap bolts and stud bolt.
94. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).
95. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.
96. Remove the 4 bolts and 4 piston cooling jets from the cylinder block.

MATERIAL SPECIFICATIONS

Scheme 922

ITEM DESCRIPTION

MATERIAL SPECIFICATIONS

Scheme 923

ITEM DESCRIPTION

MATERIAL SPECIFICATIONS

Scheme 924

ITEM DESCRIPTION

Scheme 925

ITEM DESCRIPTION

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

Note. During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article.

Scheme 926

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1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the rear of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 5. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing. Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5 bearing.
4. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2, 3 and 4. Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 2 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing. Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select the No. 3 and No. 4 bearings. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
5. Install the 4 piston cooling jets and 4 bolts. Tighten in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
6. Install the crankshaft main bearings. Install the crankshaft upper main bearings into the cylinder block. Install the crankshaft lower main bearings and thrust bearing into the bearing caps. Make sure all oil passages are aligned. Lubricate all main bearings with clean engine oil.
7. Install the crankshaft into the cylinder block.
8. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
9. Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap fasteners.
10. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
11. Tighten the vertical main bearing cap fasteners in the sequence shown in illustration, in 4 stages. Stage 1: Tighten fasteners 1 through 20 to 20 Nm (177 lb-in). Stage 2: Tighten fasteners 1 through 10 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 11 through 20 to 65 Nm (48 lb-ft). Stage 4: Tighten fasteners 1 through 20 an additional 90 degrees.
12. Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown in illustration, in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 30 Nm (22 lb-ft). Stage 3: Tighten an additional 60 degrees.
13. Check the crankshaft end play. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
14. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
15. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(ref-439783) article.
16. Assemble the pistons. For additional information, refer to «PISTON»(ref-439771-S26536399552011120900000) in this service information.
17. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
18. Make sure the dimple in the piston faces the front of the engine.
19. Use the Piston Ring Compressor and the Connecting Rod Installers to install the connecting rod with the upper connecting rod bearing in place. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil.
20. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.
21. Position the lower bearing and connecting rod and install the new bolts loosely.
22. Repeat the previous 5 steps for each of the remaining pistons.
23. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 38 Nm (28 lb-ft). Stage 3: Tighten an additional 105 degrees.
24. Install the oil pump screen and pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
25. Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil pump over the crankshaft until seated against the block. Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners.
26. Tighten the fasteners in the sequence shown in illustration in 3 stages: Stage 1: Hand tighten. Stage 2: Tighten the bolt (1) to 10 Nm (89 lb-in), the stud bolt (2) to 25 Nm (18 lb-ft), the bolt (3) to 10 Nm (89 lb-in) and the stud bolt (4) to 20 Nm (177 lb-in). Stage 3: Tighten the bolt (1) an additional 45 degrees, the stud bolt (2) an additional 75 degrees, the bolt (3) an additional 45 degrees and the stud bolt (4) an additional 60 degrees.
27. Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.
28. Install the crankshaft rear seal retainer plate and the 6 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.
29. Inspect the oil pan and engine sealing surfaces. Clean the mating surfaces of the engine and oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
30. Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.
31. Position the oil pan baffle and gasket.
32. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
33. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
34. Install the oil pan and tighten the fasteners in sequence in 3 stages. Stage 1: Tighten to 2 Nm (18 lb-in) Stage 2: Tighten to 10 Nm (89 lb-in). Stage 3: Tighten an additional 45 degrees.
35. Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten the bolts in 2 stages. Stage 1: Tighten the bolts to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
36. Install a new oil filter. Tighten to 16 Nm (142 lb-in).
37. Position the CKP sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
38. Install the 2 Knock Sensor (KS) and 2 bolts. Tighten to 20 Nm (177 lb-in).
39. Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the flange facing forward.
40. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
41. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown in illustration. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 40 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees. Stage 4: Tighten an additional 90 degrees.
42. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
43. Install 8 new RH exhaust manifold studs. Tighten to 25 Nm (18 lb-ft).
44. Install new gaskets, the RH exhaust manifold and 8 new nuts. Tighten early build (coarse thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 28 Nm (21 lb-ft). Stage 2: Tighten to 37 Nm (27 lb-ft). Tighten late build (fine thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 24 Nm (18 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
45. Install the Cylinder Head Temperature (CHT) sensor. Tighten to 11 Nm (97 lb-in).
46. Using a new O-ring seal, install the coolant outlet pipe. Tighten to 10 Nm (89 lb-in).
47. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown in illustration. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 40 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees. Stage 4: Tighten an additional 90 degrees.
48. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
49. Install 8 new LH exhaust manifold studs. Tighten to 25 Nm (18 lb-ft).
50. Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten early build (coarse thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 28 Nm (21 lb-ft). Stage 2: Tighten to 37 Nm (27 lb-ft). Tighten late build (fine thread) nuts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 24 Nm (18 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
51. Using a new gasket, install the coolant outlet and 2 bolts. Tighten to 10 Nm (89 lb-in).
52. Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
53. Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in illustration in the illustration.
54. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
55. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time
56. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten an additional 45 degrees.
57. Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
58. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links. The timing mark on the exhaust VCT assembly should align with the single colored link.
59. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11 o'clock position.
60. Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts. If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
61. Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts. Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
62. Install the LH primary timing chain. Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
63. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
64. Install the LH timing chain guide and bolt. Tighten to 10 Nm (89 lb-in).
65. Install the LH timing chain tensioner arm.
66. Compress the primary timing chain tensioner plunger, using an edge of a vise.
67. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.
68. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.
69. Install the LH primary timing chain tensioner and 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the holding pin from the tensioner.
70. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.
71. Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
72. Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
73. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
74. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time.
75. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten an additional 45 degrees.
76. Install the VCT system oil filter in the intake and exhaust camshafts.
77. Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links. The timing mark on the exhaust VCT assembly should align with the single colored link.
78. Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 1 o'clock position.
79. Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts. If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
80. Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts. Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
81. Install the RH primary timing chain. Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
82. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
83. Install the RH timing chain guide and bolt. Tighten to 10 Nm (89 lb-in).
84. Install the RH timing chain tensioner arm.
85. Install the RH primary timing chain tensioner and 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the holding pin from the tensioner.
86. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.
87. Fully depress the VCT variable force solenoid pins.
88. Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.
89. Using new gaskets, position the engine front cover onto the dowels. Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts finger-tight.
90. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.
91. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.
92. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
93. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
94. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.
95. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages: Stage 1: Tighten to 140 Nm (103 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 100 Nm (74 lb-ft). Stage 4: Tighten an additional 90 degrees.
96. Install the generator, the bolt and the nut. Tighten to 48 Nm (35 lb-ft).
97. Install the accessory drive belt tensioner and the bolt. Tighten to 48 Nm (35 lb-ft).
98. Attach the 3 wiring harness retainers (2 shown in illustration) from the engine front cover and stud bolts.
99. Using a new O-ring seal, install the coolant pump and the 4 bolts. Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.
100. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
101. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
102. Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal (s).
103. Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.
104. Position the LH valve cover and new gasket on the cylinder head. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
105. Install the oil level indicator.
106. Install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in). Connect the LH intake and exhaust CMP sensor electrical connectors.
107. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
108. Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal (s).
109. Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.
110. Position the RH valve cover and new gasket on the cylinder head. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
111. Install the RH intake and exhaust CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in). Connect the RH intake and exhaust CMP sensor electrical connectors.
112. 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.
113. Install the 8 ignition coils and 8 bolts. Tighten to 6 Nm (53 lb-in).
114. Attach the 9 wiring harness retainers to the RH valve cover and the 10 wiring harness retainers to the LH valve cover.
115. Connect the 8 ignition coil electrical connectors.
116. Connect the 4 VCT variable force solenoid electrical connectors.
117. Connect the CHT sensor and the CKP sensor electrical connectors.
118. Connect the 2 KS electrical connectors.
119. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.
120. Connect the oil level sensor electrical connector and the 2 wiring harness retainers.
121. Install the Engine Lifting Bracket.
122. Using the Heavy Duty Floor Crane, remove the engine from the work stand.
123. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
124. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
125. Install the crankshaft sensor ring.
126. Install the engine separator plate, the flywheel or flexplate and the 8 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
127. If equipped, use 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.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 1009

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1. Lubricate the end of the transmission shaft with Premium Long-Life Grease.
2. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.
3. Install the transmission-to-engine stud bolt.
4. Install the Engine Support Bar. Attach the Engine Support Bar to the through bolt on the Engine Lifting Bracket. Once the engine is supported by the Engine Support Bar remove the Heavy Duty Floor Crane.
5. Using the Engine Support Bar, level the engine in the vehicle.
6. Install RH transmission-to-engine bolt.
7. Install the 3 LH transmission-to-engine bolts. Tighten the 4 installed transmission-to-engine bolts and the stud bolt to 48 Nm (35 lb-ft).
8. Install the 2 separator plate bolts. Tighten to 35 Nm (26 lb-ft).
9. Remove the 3 bolts and lower the underbody shield.
10. Install the A/C compressor and the 3 stud bolts. Tighten to 25 Nm (18 lb-ft).
11. Install the LH engine support insulator bracket, the 3 bolts and the stud bolt. Tighten to 55 Nm (41 lb-ft).
12. Position the steering intermediate shaft and install the bolt. Tighten to 47 Nm (35 lb-ft).
13. Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
14. Install the ground strap and the nut to the RH engine support insulator bracket. Tighten to 48 Nm (35 lb-ft).
15. Attach the wiring harness retainers to A/C compressor stud bolts and the RH side of the oil pan.
16. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
17. Using the Engine Support Bar, lower the engine onto the engine support insulators.
18. Install the RH and LH engine support insulator nuts. Tighten to 63 Nm (46 lb-ft).
19. Remove the Engine Support Bar and the Engine Lifting Bracket.
20. Install the top transmission-to-engine bolt and stud bolt. Tighten to 48 Nm (35 lb-ft).
21. Install the A/C belt and the accessory drive belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
22. Connect the middle PCM electrical connector, the 16 pin electrical connector and attach the wiring harness retainers to the PCM bracket.
23. Attach the wiring harness retainers to the LH side of the oil pan and the front oil pan stud bolts and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
24. Position the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
25. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
26. Using new gaskets, position the catalytic converter/H-pipe assembly.
27. Install 2 new LH catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
28. Install 2 new RH catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
29. Tighten the H-pipe clamp nuts to 48 Nm (35 lb-ft).
30. Connect the RH and LH Catalyst Monitor Sensor (CMS) electrical connectors.
31. Connect the LH and RH Heated Oxygen Sensor (HO2S) sensor electrical connectors.
32. Install the B+ cable, the nut, and the electrical connector to the generator. Tighten to 17 Nm (150 lb-in).
33. Install the engine cooling fan assembly, the bolt, and the stud bolt. Tighten to 9 Nm (80 lb-in).
34. Connect the engine cooling fan electrical connector.
35. Connect the 2 heater hose quick connect couplings to the heater core. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
36. Connect the lower radiator hose to the engine.
37. Connect the coolant bypass T assembly to the engine and install the clamp and the spring clip.
38. Install the Air Cleaner (ACL) inlet pipe.
39. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
40. Attach the Evaporative Emission (EVAP) tube to the LH valve cover and the LH inner fender.
41. Attach the fuel supply tube to the LH valve cover.
42. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-439771-S13516427442011120900000) in this service information.
43. Install the degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
44. Install the upper radiator sight shield and the 8 pin-type retainers.
45. Attach the sound enhancement pipe retainer.
46. Install the ACL outlet pipe and the ACL . For additional information, refer to the exploded view in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
47. Lift the cowl screen and install the ground strap bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
48. Install the 2 cowl vent screen plastic rivets.
49. Install the engine appearance cover.
50. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
51. Install the hood and the 4 bolts. Tighten to 12 Nm (106 lb-in).
52. Attach the 2 windshield washer hose retainers and connect the 2 windshield washer hose C-Lock Couplers. For additional information, refer to «WIPER SYSTEM & WASHER SYSTEM»(ref-439820) article.
53. Install the 2 windshield washer hose retainers and the 8 hood insulation pin-type retainers (2 shown in illustration).
54. Install the 2 steering column dash boot nuts. Tighten to 9 Nm (80 lb-in).
55. Fill the engine with clean engine oil.
56. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
57. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
58. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

MATERIAL SPECIFICATIONS

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1. Lubricate the torque converter pilot hub with multi-purpose grease.
2. Remove the Torque Converter Retainer.
3. Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
4. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.
5. Install the transmission-to-engine bolt.
6. Install the Engine Support Bar. Attach the Engine Support Bar to the through bolt on the Engine Lifting Bracket. Once the engine is supported by the Engine Support Bar remove the Heavy Duty Floor Crane.
7. Using the Engine Support Bar, level the engine in the vehicle.
8. Install the 2 LH transmission-to-engine bolts.
9. Install 2 RH transmission-to-engine bolts. Tighten the 5 installed transmission-to-engine bolts to 48 Nm (35 lb-ft).
10. Install 4 new torque converter nuts. Tighten to 40 Nm (30 lb-ft).
11. Install the rubber access plug.
12. Install the flexplate inspection cover, the bolt, and the stud bolt. Tighten to 35 Nm (26 lb-ft).
13. Remove the 3 bolts and lower the underbody shield.
14. Install the A/C compressor and the 3 stud bolts. Tighten to 25 Nm (18 lb-ft).
15. Install the LH engine support insulator bracket, the 3 bolts and the stud bolt. Tighten to 55 Nm (41 lb-ft).
16. Position the steering intermediate shaft and install the bolt. Tighten to 47 Nm (35 lb-ft).
17. Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
18. Install the ground strap and the nut to the RH engine support insulator bracket. Tighten to 48 Nm (35 lb-ft).
19. Attach the wiring harness retainers to A/C compressor stud bolts and the RH side of the oil pan.
20. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
21. Install the transmission cooler tube clamp and nut to the RH engine support insulator bracket. Tighten to 48 Nm (35 lb-ft).
22. Install the transmission fluid cooler tube bracket and nut to the flexplate inspection cover stud bolt. Tighten to 13 Nm (115 lb-in).
23. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
24. Install the lower radiator sight shield and the 9 screws.
25. Using the Engine Support Bar, lower the engine onto the engine support insulators.
26. Install the RH and LH engine support insulator nuts. Tighten to 63 Nm (46 lb-ft).
27. Remove the Engine Support Bar and the Engine Lifting Bracket.
28. Install the top transmission-to-engine bolt and stud bolt. Tighten to 48 Nm (35 lb-ft).
29. Install the A/C belt and the accessory drive belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(ref-439789) article.
30. Install the transmission cooler tube clamp bolt to the fan shroud. Tighten to 8 Nm (71 lb-in).
31. Connect the middle PCM electrical connector, the 16 pin electrical connector and attach the wiring harness retainers to the PCM bracket.
32. Attach the wiring harness retainers to the LH side of the oil pan and the front oil pan stud bolts and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
33. Position the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
34. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-439822) article.
35. Using new gaskets, position the catalytic converter/H-pipe assembly.
36. Install 2 new LH catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
37. Install 2 new RH catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
38. Tighten the H-pipe clamp nuts to 48 Nm (35 lb-ft).
39. Connect the LH and RH Catalyst Monitor Sensor (CMS) electrical connectors.
40. Connect the LH and RH Heated Oxygen Sensor (HO2S) sensor electrical connectors.
41. Install the B+ cable, the nut, and the electrical connector to the generator. Tighten to 17 Nm (150 lb-in).
42. Connect the 2 heater hose quick connect couplings to the heater core. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-439786) article.
43. Connect the lower radiator hose to the engine.
44. Connect the coolant bypass T assembly to the engine and install the clamp and the spring clip.
45. Install the Air Cleaner (ACL) inlet pipe.
46. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
47. Attach the EVAP tube to the LH valve cover and the LH inner fender.
48. Attach the fuel supply tube to the LH valve cover.
49. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-439771-S13516427442011120900000) in this service information.
50. Install the degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
51. Install the upper radiator sight shield and the 8 pin-type retainers.
52. Attach the sound enhancement pipe retainer.
53. Install the ACL outlet pipe and the ACL . For additional information, refer to the exploded view in «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(ref-439816) article.
54. Lift the cowl screen and install the ground strap bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
55. Install the 2 cowl vent screen plastic rivets.
56. Install the engine appearance cover.
57. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
58. Install the hood and the 4 bolts. Tighten to 12 Nm (106 lb-in).
59. Attach the 2 windshield washer hose retainers and connect the 2 windshield washer hose C-Lock Couplers. For additional information, refer to «WIPER SYSTEM & WASHER SYSTEM»(ref-439820) article.
60. Install the 2 windshield washer hose retainers and the 8 hood insulation pin-type retainers (2 shown in illustration).
61. Install the 2 steering column dash boot nuts. Tighten to 9 Nm (80 lb-in).
62. Fill the engine with clean engine oil.
63. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-439815) article.
64. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(ref-439830) article.
65. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

See also:
• JACKING & LIFTING
• AUTOMATIC TRANSMISSION - 6R80