Engine Mechanical - 2.3L: Other Ford Ranger II рестайлинг

Engine Code Information Label

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

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DESCRIPTION CHART

Exhaust Emission Control System

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

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the cylinder head.
2. meter fuel to the air intake stream in accordance with engine demand.
3. are positioned so their tips direct fuel just ahead of the engine intake valves.

PCV System

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

Material

MATERIAL SPECIFICATION

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1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-365413) .
3. Remove the 2 bolts and the Throttle Body (TB) shield.
4. Disconnect the acceleration control cable from the intake manifold and the TB .
5. If equipped, disconnect the speed control cable from the intake manifold and the TB .
6. Disconnect the Throttle Position (TP) sensor electrical connector.
7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
8. Disconnect the Idle Air Control (IAC) valve electrical connector.
9. Disconnect the vapor purge tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
10. Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.
11. Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.
12. Disconnect the pin-type retainer from the rear of the intake manifold.
13. Remove the EGR tube support bracket bolt.
14. Remove the 2 bolts from the EGR tube flange.
15. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
16. Disconnect the Knock Sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.
17. Remove the wiring harness pushpin from the bottom of the intake manifold.
18. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
19. 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. Remove the 5 bolts and the intake manifold. Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
20. Remove and discard the 4 intake manifold gaskets.

MATERIAL SPECIFICATION

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General Equipment

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1. NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-365364-S00731704452010070700000) .
2. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal, or oil leakage may occur. Using the Seal Remover, remove the crankshaft front seal.

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1. NOTE: Lubricate the new crankshaft front seal with clean engine oil prior to installation. Using the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-365364-S00731704452010070700000) .

GENERAL EQUIPMENT REFERENCE

MATERIAL SPECIFICATION

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1. NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-365364-S00731704452010070700000) .
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector and the wiring harness pin-type retainers.
3. NOTE: A new CKP sensor must be installed whenever the old sensor is removed. Remove and discard the CKP sensor.
4. Remove the bolt and the accessory drive belt tensioner.
5. Remove the 3 bolts and the coolant pump pulley.
6. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
7. Remove the 3 bolts and position the power steering pump aside.
8. NOTE: This step is needed only if a new front cover is being installed. Using a 3 jaw puller, remove the fan drive pulley.
9. NOTE: There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt. Remove the 21 bolts and the engine front cover.
10. 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 the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

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1. NOTE: This step is needed only if a new front cover is being installed. Install the fan drive pulley, using a nut and bolt with flat washers.
2. 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. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
3. Install the front cover. Tighten the 21 bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in). Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft). Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).
4. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
5. Connect the PSP switch electrical connector.
6. Position the coolant pump pulley and install the 3 bolts. Tighten to 20 Nm (177 lb-in).
7. Install the accessory drive belt tensioner and the bolt. Tighten to 50 Nm (37 lb-ft).
8. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-365364-S00731704452010070700000) .
9. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
10. Position a new CKP sensor and loosely install the 2 bolts.
11. Adjust the CKP with the Crankshaft Sensor Aligner, and tighten the 2 bolts. Tighten to 7 Nm (62 lb-in).
12. Remove the 6 mm x 18 mm bolt.
13. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-365381) .
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .
5. Remove the 2 exhaust downpipe flange nuts.
6. Disconnect the upper radiator hose and the degas bottle coolant hose from the front coolant outlet pipe.
7. If equipped, remove the A/C compressor. For additional information, refer to «CLIMATE CONTROL»(ref-365421) .
8. Disconnect the heater coolant hose from the front coolant outlet pipe.
9. Remove the oil level indicator, the 2 bolts and the oil level indicator tube. Discard the O-ring seal.
10. Remove the 2 bolts and the front coolant outlet pipe. Discard the O-ring seal.
11. Remove the 5 pushpins and position the right inner fender splash shield aside.
12. Disconnect the generator electrical connections and, if equipped with A/C, the wiring harness retainer.
13. Remove the 5 bolts and the generator and support bracket assembly.
14. Remove the 2 nuts and position the coolant tube aside.
15. Remove the 7 nuts, the exhaust manifold and the gasket. Discard the exhaust manifold nuts and the gasket.
16. Remove and discard the 7 exhaust manifold-to-cylinder head studs.
17. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .
18. 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. Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.

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1. Install 7 new exhaust manifold-to-cylinder head studs. Tighten to 17 Nm (150 lb-in).
2. Install a new exhaust manifold gasket.
3. Position the exhaust manifold and install 7 new nuts. Tighten to 54 Nm (40 lb-ft).
4. Position the coolant tube and install the 2 nuts. Tighten to 20 Nm (177 lb-in).
5. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown in illustration, in 2 stages. Stage 1: Install finger-tight. Stage 2: Tighten to 47 Nm (35 lb-ft).
6. Connect the generator electrical connections and, if equipped with A/C, the wiring harness retainer. Tighten the battery cable nut to 12 Nm (106 lb-in).
7. Position the right inner splash shield and install the 5 pushpins.
8. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation. Using a new O-ring seal, position the front coolant outlet pipe and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
9. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, position the oil level indicator tube assembly and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the oil level indicator.
11. Connect the heater coolant hose to the front coolant outlet pipe.
12. If equipped, install the A/C compressor. For additional information, refer to «CLIMATE CONTROL»(ref-365421) .
13. Connect the upper radiator hose and the degas bottle coolant hose to the front coolant outlet pipe.
14. Install the 2 exhaust downpipe flange nuts. Tighten to 40 Nm (30 lb-ft).
15. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-365381) .
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
17. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Remove the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-365412) .
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-365364-S28043611372010070700000) .
4. NOTE: Only the LH side of the engine will be raised. Remove the LH engine support insulator-to-engine bracket nuts.
5. Install the Lifting Eye.
6. Install the 3-Bar Engine Support Kit and raise the LH side of the engine approximately 25 mm (1 in).
7. Remove the drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 28 Nm (21 lb-ft).
8. Detach the 2 wiring harness retainers from the engine front cover.
9. Remove the 4 engine front cover-to-oil pan bolts.
10. Remove the transmission bracket-to-transmission bolts.
11. Remove the 4 transmission-to-oil pan bolts.
12. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.19 in). Loosen the 7 transmission-to-cylinder block bolts 5 mm (0.19 in).
13. Slide the transmission rearward 5 mm (0.19 in).
14. NOTE: If necessary, lift the rear of the transmission to remove the oil pan. Remove the 13 oil pan bolts and the oil pan.
15. 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 the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

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1. 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 sealant. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: If necessary, lift the rear of the transmission to install the oil pan. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Position the oil pan and install the 13 bolts finger-tight.
2. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
3. Tighten the 13 oil pan bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
4. Attach the 2 wiring harness retainers to the engine front cover.
5. Slide the transmission forward and tighten the 7 transmission-to-cylinder block bolts. Tighten to 48 Nm (35 lb-ft).
6. Install the 4 transmission-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
7. Install the transmission bracket-to-transmission bolts. Tighten to 90 Nm (66 lb-ft).
8. Lower the engine and remove the 3-Bar Engine Support Kit and the Lifting Eye.
9. Install the engine support insulator nuts. Tighten to 102 Nm (75 lb-ft).
10. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-365364-S28043611372010070700000) .
11. Install the engine cooling fan. For additional information, refer to «ENGINE COOLING»(ref-365412) .
12. Install a new oil filter.
13. Fill the engine with clean engine oil.

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RH Splash Shield

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Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

Note. During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.

Note. Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Note. For additional information, refer to the exploded views in ASSEMBLY .

Vehicles with manual transmission

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1. NOTE: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch release. NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel. Remove the 6 bolts, the clutch pressure plate and the clutch disc. All vehicles
2. Using the Flywheel Locking Tool, remove the 6 bolts and the flexplate or flywheel.
3. Mount the engine on a suitable engine stand.
4. Remove the drive belt.
5. Remove the engine oil level indicator, the 2 bolts and the engine oil level indicator tube.
6. Remove the 2 bolts and the front coolant outlet pipe.
7. Remove the 4 bolts and the A/C compressor.
8. NOTE: The generator will be removed with the accessory bracket. Remove the 5 bolts and the accessory bracket and generator as an assembly.
9. Remove the 4 bolts and the RH engine mount bracket.
10. Disconnect the coolant hose assembly from the thermostat housing and the PCV fitting on the intake manifold.
11. Remove the 2 nuts and the coolant tube assembly.
12. Remove the 7 nuts, the exhaust manifold and gasket. Discard the 7 nuts and the exhaust manifold gasket.
13. Remove and discard the 7 exhaust manifold-to-cylinder head studs.
14. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .
15. If equipped, remove the block heater.
16. Remove the rear coolant outlet pipe. Disconnect the coolant hose. Remove the 4 bolts, the rear coolant outlet pipe and discard the gasket.
17. Remove the EGR valve. Disconnect the electrical connector. Disconnect the coolant hose. Remove the 2 bolts, the EGR valve and discard the gasket.
18. Remove the 4 bolts and the power steering pump.
19. Disconnect the Idle Air Control (IAC) valve, the Throttle Position (TP) sensor and the Manifold Absolute Pressure (MAP) sensor electrical connectors.
20. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.
21. Disconnect the Knock Sensor (KS) electrical connector, remove the 3 bolts and position the engine wiring harness and bracket aside.
22. Disconnect the Camshaft Position (CMP) sensor electrical connector and the PCV hose.
23. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
24. Remove the 2 bolts and the EGR tube from the intake manifold.
25. Remove the EGR tube. Remove the EGR tube bracket bolt from the intake manifold. Disconnect the EGR tube from the cylinder head. Remove the EGR tube.
26. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. 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. Remove the 5 bolts and the intake manifold. Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
27. Disconnect the 4 fuel injector electrical connectors and the 2 wiring harness pin-type retainers.
28. Disconnect the ignition coil and the Cylinder Head Temperature (CHT) sensor electrical connectors.
29. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
30. NOTE: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. Failure to follow this instruction may result in poor engine performance. NOTE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. With a twisting motion, disconnect the spark plug wires from the spark plugs.
31. Remove the 4 bolts and the ignition coil.
32. Remove the 3 bolts and the thermostat housing.
33. Remove the 9 bolts, the KS and the engine vent cover.
34. Remove the 4 bolts and the LH engine mount bracket.
35. Remove the 2 bolts, fuel rail with the injectors and the ground strap. Discard the fuel injector O-ring seals.
36. Remove the 3 bolts and the coolant pump pulley.
37. Remove the 3 bolts and the coolant pump. Discard the O-ring seal.
38. Remove the CMP sensor, CHT sensor and the spark plugs.
39. Remove the 14 fasteners and the valve cover.
40. Remove the 2 bolts and discard the CKP sensor.
41. NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur. NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine. NOTE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
42. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
43. NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
44. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using the Oil Seal Remover, remove the crankshaft front oil seal.
45. NOTE: There is one engine front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head. Remove the 20 bolts, the stud bolt and the engine front cover.
46. Compress the timing chain tensioner in the following sequence. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a paper clip into the hole to retain the tensioner.
47. Remove the 2 bolts and the timing chain tensioner.
48. Remove the RH timing chain guide.
49. Remove the timing chain.
50. Remove the 2 bolts and the LH timing chain guide.
51. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft may occur. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place. Remove the 2 bolts, 2 washers and camshaft drive sprockets.
52. Remove the oil pump chain drive tensioner. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner.
53. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket. NOTE: The oil pump chain sprocket must be held in place. Remove the bolt, the chain, sprockets and diamond washers.
54. Remove the Camshaft Alignment Plate.
55. NOTE: Failure to follow the camshaft loosening procedure may result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference. Remove the camshaft bearing caps. Loosen the 20 camshaft bearing cap bolts in sequence shown in illustration, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps.
56. Remove the camshafts.
57. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is removed. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Foreign material, including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are torque-to-yield designed and cannot be reused. Remove the 10 bolts and the cylinder head. Discard the cylinder head bolts.
58. Remove and discard the cylinder head gasket.
59. Remove the cylinder head alignment dowels.
60. Remove the 13 bolts and the oil pan.
61. Remove the 6 bolts and the rear crankshaft seal and retainer plate. Discard the crankshaft rear seal and retainer plate assembly.
62. Remove the 4 bolts, the oil pump pickup tube and discard the gasket.
63. Remove the 4 bolts and the oil pump assembly. Discard the gasket.
64. 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.
65. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly. Remove the connecting rod cap bolts and cap.
66. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
67. Remove the bolts in the sequence shown in illustration. Remove the main bearing beam. Discard the bolts.
68. Remove the crankshaft from the engine block.
69. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. Remove the main bearings from the main bearing beam.
70. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing. Remove the main bearings from the cylinder block.
71. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter. Remove the 4 oil squirters.
72. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .

MATERIAL SPECIFICATION

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1. Remove the 2 bolts and the engine lifting eyes.
2. Remove the Cylinder Head Temperature (CHT) sensor.
3. Remove the 4 bolts and the coolant outlet pipe. Discard the gasket.
4. Remove the 2 bolts and the EGR valve. Discard the EGR valve gasket.
5. Remove and discard the 4 spark plugs.
6. NOTE: Note location of the tappets prior to removal. Remove the 16 valve tappets.
7. Using the 3 Valve Spring Compressors, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers and the valve springs.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) . Install new parts as necessary.
9. NOTE: Note the location of the valves if they are to be reused. NOTE: Mark each valve if the original valves are to be used. Remove the valves.
10. Using the Valve Stem Seal Remover and the Slide Hammer, remove and discard the valve stem seals.
11. Inspect the valves. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) . Install new parts as necessary.

MATERIAL SPECIFICATION

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Note. During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.

Note. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley is loosened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage may occur.

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

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1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Install the 4 oil squirters. Tighten to 4 Nm (35 lb-in).
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. 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. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: The center bulkhead is the thrust bearing. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts. Install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.
20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Install the connecting rod caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
21. NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine. NOTE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
22. Remove the timing peg plug.
23. NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain in the TDC position during the crankshaft pulley removal and installation. Install the Crankshaft Timing Peg.
24. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep. Position the oil pump assembly and tighten the 4 bolts in the sequence shown in illustration, in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
25. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep. Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
26. Using the Crankshaft Rear Main Oil Seal Installer, install the a new crankshaft rear seal and retainer plate assembly.
27. Tighten the 6 crankshaft rear seal and retainer plate assembly bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
28. 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 sealant. NOTE: Clean the sealing surface with metal surface prep and silicone gasket remover. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep and the silicone gasket remover. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the 13 oil pan bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
29. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder 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.
30. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .
31. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
32. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the locations shown in illustration.
33. Install a new cylinder head gasket.
34. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the cylinder head bolts with clean engine oil. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration, in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Tighten an additional 90 degrees (one-fourth turn). Stage 5: Tighten an additional 90 degrees (one-fourth turn).
35. NOTE: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position may cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts and bearing caps in their original location and orientation. Tighten the 20 bearing cap bolts in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
36. NOTE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The new diamond washers must be installed correctly, or severe engine damage may result. Install the new diamond washers and the oil pump chain and sprockets. The crankshaft sprocket flange must be facing away from the engine block.
37. NOTE: The oil pump chain sprocket must be held in place. Tighten the oil pump sprocket bolt. Tighten to 25 Nm (18 lb-ft).
38. Install the oil pump chain drive tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
39. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt and tighten the tensioner bolt. Tighten to 10 Nm (89 lb-in).
40. NOTE: Sprockets must turn freely on the camshafts. Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this time. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
41. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger.
42. Using a small pick, push back and hold the ratchet mechanism.
43. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
44. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
45. Install the timing chain.
46. Position the timing chain guides and install the 2 LH guide bolts. Tighten to 10 Nm (89 lb-in).
47. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to apply tension to the timing chain. Tighten to 10 Nm (89 lb-in).
48. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage. Install the Camshaft Alignment Plate in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
49. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place. Tighten the camshaft sprocket bolts. Tighten to 72 Nm (53 lb-ft).
50. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Clean the engine front cover gasket surface with silicone gasket remover and metal surface prep.
51. 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. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
52. 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. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the locations shown in illustration.
53. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Install the front cover. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in). Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft). Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).
54. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. NOTE: Lubricate the crankshaft front seal with clean engine oil. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
55. NOTE: Do not install the crankshaft pulley bolt at this time. NOTE: Apply clean engine oil to the seal area prior to installing. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
56. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
57. NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Rotate an additional 90 degrees.
58. Remove the 6 mm x 18 mm bolt.
59. Remove the Crankshaft Timing Peg.
60. Remove the Camshaft Alignment Plate.
61. NOTE: Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft clockwise one and three-fourths turn.
62. Install the Crankshaft Timing Peg.
63. NOTE: Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.
64. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
65. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, correct the engine timing.
66. Remove the Camshaft Alignment Plate.
67. Position a new Crankshaft Position (CKP) sensor and loosely install the 2 bolts.
68. Adjust the CKP with the Crankshaft Sensor Aligner, the tool must engage a tooth of the vibration damper, and tighten the 2 bolts. Tighten to 7 Nm (62 lb-in).
69. Remove the 6 mm x 18 mm bolt.
70. Remove the Crankshaft Timing Peg.
71. Install the timing peg plug. Tighten to 20 Nm (177 lb-in).
72. 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 the valve cover gasket sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
73. 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. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the locations shown in illustration.
74. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Install the valve cover and the 14 fasteners. Tighten to 10 Nm (89 lb-in).
75. Install the following: Crankshaft Position (CKP) sensor and the bolt Tighten to 7 Nm (62 lb-in). Cylinder Head Temperature (CHT) sensor Tighten to 12 Nm (106 lb-in). Spark plugs Tighten to 15 Nm (133 lb-in).
76. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. NOTE: Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly. Using a new O-ring seal, install the coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
77. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (177 lb-in).
78. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil prior to installation. Using new O-ring seals, install the fuel rail and fuel injectors as an assembly, the ground strap and the bolt. Tighten the 2 fuel rail bolts to 25 Nm (18 lb-ft). Tighten ground strap bolt to 10 Nm (89 lb-in).
79. Install the left motor mount and the 4 bolts. Tighten to 49 Nm (36 lb-ft).
80. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator. Install the crankcase vent oil separator, the KS and the 9 bolts. Tighten the KS bolt to 20 Nm (177 lb-in). Tighten the 8 crankcase vent oil separator bolts to 10 Nm (89 lb-in).
81. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
82. Install the ignition coil and the 4 bolts. Tighten to 6 Nm (53 lb-in).
83. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots prior to installation. Connect the spark plug wires to the spark plugs.
84. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
85. Connect the ignition coil and the CHT sensor electrical connectors. Position the CHT sensor cover.
86. Connect the fuel injector electrical connectors and attach the wiring harness pin-type retainers.
87. Inspect and install new intake manifold gaskets, if necessary.
88. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Install the intake manifold and the 5 bolts. Tighten to 18 Nm (159 lb-in).
89. Install the EGR tube. Install the EGR tube bracket and the bolt to the intake manifold. Tighten to 10 Nm (89 lb-in). Connect the EGR tube to the cylinder head. Tighten to 55 Nm (41 lb-ft).
90. Connect the EGR tube to the intake manifold. Tighten to 18 Nm (159 lb-in).
91. Attach the engine wiring harness pin-type retainers to the intake manifold.
92. Connect the CMP sensor electrical connector and the PCV hose.
93. Install the engine wiring harness connector bracket, the 3 bolts and connect the KS electrical connector. Tighten to 10 Nm (89 lb-in).
94. Connect the CKP sensor electrical connection and attach the wiring pin-type retainers.
95. Connect the following electrical connectors: Manifold Absolute Pressure (MAP) sensor Throttle Position (TP) sensor Idle Air Control (IAC) valve
96. Install the power steering pump assembly and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
97. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Install the EGR valve. Using a new gasket, position the EGR valve and install the 2 bolts. Tighten to 20 Nm (177 lb-in). Connect the coolant hose. Connect the electrical connector.
98. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Install the rear coolant outlet pipe. Using a new gasket, install the rear coolant outlet pipe and the 4 bolts. Tighten to 10 Nm (89 lb-in). Connect the coolant hose.
99. If equipped, install the block heater.
100. Install 7 new exhaust manifold-to-cylinder head studs. Tighten to 17 Nm (150 lb-in).
101. Position a new gasket and install the exhaust manifold and 7 new nuts. Tighten to 54 Nm (40 lb-ft).
102. Position the coolant tube assembly and install the 2 nuts. Tighten to 20 Nm (177 lb-in).
103. Connect the coolant hose to the thermostat and the PCV fitting on the intake manifold.
104. Position the right motor mount and install the 4 bolts. Tighten to 49 Nm (36 lb-ft).
105. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown in illustration, in 2 stages. Stage 1: Install finger-tight. Stage 2: Tighten to 47 Nm (35 lb-ft).
106. Position the A/C compressor and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
107. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation. Position the front coolant outlet pipe and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
108. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Install the engine oil level indicator tube and the bolt. Tighten to 10 Nm (89 lb-in).
109. Install the accessory drive belt.
110. Using the Spreader Bar and the Heavy Duty Floor Crane, remove the engine from the Engine Stand.
111. Position the flywheel or the flexplate and loosely install the 6 bolts.
112. Using the Flywheel Locking Tool, tighten the 6 bolts in the sequence shown in illustration, in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft). Vehicles with manual transmission
113. Lubricate the transmission input shaft pilot bearing with front axle grease.
114. Adjust the clutch pressure plate. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
115. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
116. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Position the clutch pressure plate and install the 6 bolts. Tighten the bolts in a star pattern sequence. Tighten to 32 Nm (24 lb-ft).

MATERIAL SPECIFICATION

All vehicles

Scheme 243

Scheme 244

1. Position the engine in the vehicle. If equipped with an automatic transmission, make sure the index marks on the torque converter stud and flexplate made during removal are lined up.
2. Install the 2 side transmission-to-engine bolts.
3. NOTE: Left side shown in illustration, right side similar. Install the 4 engine support insulator nuts. Tighten to 102 Nm (75 lb-ft).
4. Remove the floor jack from the transmission.
5. Remove the Heavy Duty Floor Crane, the Spreader Bar and the Engine Lifting Brackets. Vehicles with an automatic transmission
6. Install the 4 torque converter nuts. Tighten to 35 Nm (26 lb-ft).
7. Install the transmission fluid indicator and tube assembly. All vehicles
8. Install the remaining 9 transmission-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
9. Position the oil filter adapter and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
10. Install the starter dust shield.
11. Install the starter, the bolt and the 2 stud bolts. Tighten to 25 Nm (18 lb-ft).
12. Install a new oil filter.
13. Connect the Engine Oil Pressure (EOP) sensor electrical connector. Vehicles with an automatic transmission
14. Attach the wiring harness retainers.
15. Attach the wiring harness retainers and connect the transmission electrical connectors.
16. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the Catalyst Monitor Sensor (CMS) electrical connector. Tighten to 10 Nm (89 lb-in).
17. Connect the Heated Oxygen Sensor (HO2S) electrical connector. Vehicles with a manual transmission
18. Attach the wiring harness retainers and connect the transmission electrical connectors.
19. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the CMS electrical connector. Tighten to 10 Nm (89 lb-in).
20. Connect the HO2S electrical connector. All vehicles
21. Connect the electrical connector and attach the wiring harness retainer to the crossmember.
22. Position the exhaust front pipe and install the 2 nuts. Tighten to 40 Nm (30 lb-ft).
23. Position the transmission dust shield and install the bolt. Tighten to 10 Nm (89 lb-in). Vehicles with an automatic transmission
24. Install the transmission cooling tubes retaining bracket and the bolt. Tighten to 28 Nm (21 lb-ft). All vehicles
25. Position the engine wiring harness and install the anchor and the pin-type retainer.
26. If equipped, connect the block heater electrical connector.
27. Attach the generator wiring pin-type retainer.
28. Connect the generator electrical connections. Tighten to 12 Nm (106 lb-in).
29. Position the RH splash shield and install the 3 rear pushpins.
30. Position the starter wiring harness and install the support bracket and the bolt. Tighten to 24 Nm (18 lb-ft).
31. Connect the following starter motor electrical connections. Install the solenoid control wire and nut. Tighten to 6 Nm (53 lb-in). Install the negative battery cable and nut. Tighten to 12 Nm (106 lb-in). Install the positive battery cable at the starter and the nut. Tighten to 12 Nm (106 lb-in).
32. Connect the brake booster vacuum hose and the engine ground strap. Tighten to 10 Nm (89 lb-in).
33. Connect the electrical connectors, the fuel supply tube and the evaporative purge tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
34. Connect the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
35. NOTE: Install a new nylon O-ring seal. Connect the power steering high-pressure tube and the Power Steering Pressure (PSP) switch electrical connector. Tighten to 20 Nm (177 lb-in).
36. Connect the accelerator cable and, if equipped, the speed control cable to the Throttle Body (TB) and the cable mounting bracket.
37. Remove the plugs and connect the A/C compressor manifold. Tighten to 20 Nm (177 lb-in).
38. Connect the Mass Air Flow (MAF) sensor electrical connector.
39. Connect the A/C compressor electrical connector.
40. Connect the coolant reservoir-to-engine supply hose.
41. Connect the engine-to-coolant reservoir bypass hose.
42. Connect the vacuum reservoir tube.
43. Install the heater hose assembly. Connect the heater hoses to the heater core. Connect the vacuum hose. Connect the heater hoses to the engine.
44. Install the ground strap and stud bolt. Tighten to 10 Nm (89 lb-in).
45. Position the PCM harness, install the harness retaining nut and connect the 3 PCM electrical connectors. Tighten the harness retainer nut to 4 Nm (35 lb-in).
46. Install the lower radiator hose.
47. Install the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-365412) .
48. Install the upper radiator hose.
49. Install the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-365413) .
50. Install the hood.
51. Fill the engine with clean engine oil.
52. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
53. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .
54. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-365379) .
55. Evacuate and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-365378) .