Engine - 3.0L (2V): Other Ford Taurus IV рестайлинг

Material

MATERIAL ITEM SPECIFICATION

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1. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233700) .
3. Remove the push rods. For additional information, refer to «PUSH ROD»(ref-233691-S27617878052006052600000) .
4. Disconnect the fuel rail pressure (FRP) sensor electrical and vacuum connections.
5. Disconnect the fuel injector electrical connectors.
6. Disconnect the heater hose and engine coolant temperature (ECT) sender electrical connector.
7. Disconnect the ECT sensor electrical connector and the degas bottle hose.
8. Disconnect the upper radiator hose from the thermostat housing.
9. Remove the bolts and the lower intake manifold.
10. Remove the intake manifold gaskets and the end seals.

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1. Using metal surface cleaner, clean all the sealing surfaces.
2. Apply silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
3. Install the lower intake manifold gaskets and end seals. Position the intake manifold gaskets. Position the intake manifold end seals.
4. Install the intake manifold. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
5. Connect the upper radiator hose to the thermostat housing.
6. Connect the engine coolant temperature (ECT) sensor electrical connector and the degas bottle hose.
7. Connect the heater hose and the ECT sender electrical connector.
8. Connect the fuel injector electrical connectors.
9. Connect the fuel rail pressure (FRP) sensor electrical and vacuum connections.
10. Install the push rods. For additional information, refer to «PUSH ROD»(ref-233691-S27617878052006052600000) .
11. Connect the fuel tube spring lock coupling. For additional information, refer to «FUEL TANK & LINES»(ref-233736) .
12. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233700) .

MATERIAL ITEM SPECIFICATION

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1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233691-S34789236842006052600000) .
2. Lift the degas bottle hose off the valve cover studs and position the hose aside.
3. Lift the fuel charging wiring harness off the valve cover studs and position the wiring harness aside.
4. Position the spark plug wires aside.
5. Remove the RH valve cover.

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1. Using metal surface cleaner, clean the cylinder head mating surfaces.
2. Apply a bead of silicone gasket and sealant in two places where the cylinder head and intake manifold meet.
3. Install the valve cover gasket, if removed.
4. Install the RH valve cover.
5. Route the spark plug wires.
6. Install the fuel charging wiring harness.
7. Install the degas bottle hose.
8. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233691-S34789236842006052600000) .

MATERIAL ITEM SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
2. Remove the ignition coil. For additional information, refer to «ENGINE IGNITION - 3.0L (2V)»(ref-233737) .
3. Disconnect the crankcase ventilation hose.
4. Release the wiring harness from the valve cover studs and position aside.
5. Release the wiring harness from the valve cover studs and position aside.
6. Position the spark plug wires aside.
7. Remove the LH valve cover.

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1. Using metal surface cleaner, clean the cylinder head mating surfaces.
2. Apply a bead of silicone gasket and sealant in two places where the cylinder head and intake manifold meet.
3. Install the valve cover gasket, if removed.
4. Install the valve cover.
5. Route the spark plug wires.
6. Install the engine wiring harness.
7. Install the engine wiring harness.
8. Connect the crankcase vent tube.
9. Install the ignition coil. For additional information, refer to «ENGINE IGNITION - 3.0L (2V)»(ref-233737) .
10. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .

MATERIAL ITEM SPECIFICATION

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1. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
2. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
3. Remove the RH front wheel.
4. Remove the splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-233729) .
5. Disconnect and remove the crankshaft position (CKP) sensor.
6. Remove the bolts and the crankshaft pulley.
7. Remove the crankshaft damper bolt and washer.
8. Using the special tool, remove the crankshaft damper.

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1. Install the crankshaft damper. Coat the sealing surfaces of the crankshaft damper with clean engine oil. Coat the crankshaft damper keyway with silicone gasket and sealant. Install the crankshaft damper.
2. Install the crankshaft damper bolt and the washer.
3. Install and connect the crankshaft position (CKP) sensor.
4. Install the crankshaft pulley.
5. Install the splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-233729) .
6. Install the RH front wheel.
7. Lower the vehicle.
8. Install the accessory drive belt. For additional information, refer to

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

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1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-233700) .
2. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
3. Remove the engine anti-roll strut brace. Remove the nuts. Remove the brace.
4. Remove the engine anti-roll strut. Remove the bolts.
5. Remove the coolant expansion tank (8A080). For additional information, refer to «ENGINE COOLING»(ref-233700) .
6. Loosen the four water pump pulley bolts.
7. Remove the crankshaft damper (6316). For additional information, refer to «CRANKSHAFT PULLEY»(ref-233691-S27699543092006052600000) .
8. Disconnect the lower radiator hose. Reposition the clamp. Disconnect the hose.
9. Remove the crankshaft position (CKP) sensor (6C315). Disconnect the sensor. Remove the bolts. Remove the sensor.
10. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-233691-S12031829252006052600000) .
11. Lower the vehicle.
12. Disconnect the generator (10346).
13. Remove the generator support bracket. Remove the nut. Remove the bolt.
14. Remove the generator. Remove the stud bolt.
15. Remove the accessory drive belt idler pulley. Remove the bolt.
16. Remove the accessory drive belt tensioner (6B209). Remove the bolt.
17. Remove the A/C compressor bracket. Remove the nut. Remove the bolt.
18. Disconnect the heater hose (18472). Reposition the clamp. Disconnect the hose.
19. Remove the water pump pulley (8509). Remove the bolts. Remove the pulley.
20. Remove the engine front cover (6059) and water pump (8501) as an assembly. Remove the bolts. Remove the front cover.
21. Remove and discard the front cover gasket (6020).

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1. Clean all sealing surfaces and position a new front cover gasket.
2. Install the engine front cover and water pump assembly. Apply Pipe Sealant with Teflon® to the bolts indicated. Install the bolts.
3. Install the water pump pulley.
4. Connect the heater hose. Connect the hose. Position the clamp.
5. Install the A/C compressor bracket. Position the bracket. Install the bolt. Install the nut.
6. Install the accessory drive belt tensioner.
7. Install the accessory drive belt idler pulley.
8. Install the generator. Install the stud bolt.
9. Install the generator support bracket. Position the bracket. Install the bolt. Install the nut.
10. Connect the generator.
11. Raise the vehicle on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
12. Install the crankshaft position (CKP) sensor. Position the sensor. Install the bolts. Connect the connector.
13. Connect the lower radiator hose. Connect the hose. Reposition the clamp.
14. Install the oil pan. For additional information, refer to «OIL PAN»(ref-233691-S12031829252006052600000) .
15. Install the crankshaft damper. For additional information, refer to «CRANKSHAFT PULLEY»(ref-233691-S27699543092006052600000) .
16. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-233700) .
17. Install the engine anti-roll strut.
18. Install the engine anti-roll strut brace.
19. Connect the battery.
20. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-233700) .

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1. Remove the LH and the RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-233691-S39957448592006052600000) and «VALVE COVER - RH»(ref-233691-S15295014432006052600000) .
2. Remove the bolts and the rocker arms.
3. To install, reverse the removal procedure. Tighten the rocker arm bolts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 32 Nm (24 lb-ft).

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

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1. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
2. Disconnect the heated oxygen sensor (HO2S) (9F472) electrical connector.
3. Remove the oil level indicator tube (6754). Remove the nut. Remove the tube.
4. Disconnect the power steering pressure line (3A714) from the power steering pump. Loosen the compression nut.
5. Position the power steering pressure line aside. Remove the nut.
6. Separate the dual converter Y-pipe from the exhaust manifold. Remove the nuts.
7. Remove the four exhaust manifold bolts and two stud bolts.
8. Remove the exhaust manifold and the exhaust manifold gasket (9448). Discard the exhaust manifold gasket.

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1. Position a new exhaust manifold gasket (9448) and install the exhaust manifold.
2. Install the bolts. Tighten the bolts in sequence in two stages: Tighten to 10 Nm (8 lb-ft). Tighten to 22 Nm (16 lb-ft).
3. Connect the dual converter Y-pipe to the exhaust manifold. Install the nuts.
4. Reposition the power steering pressure line and install the nut.
5. Using the special tool, install a new seal on the power steering pressure line.
6. Connect the power steering pressure line to the power steering pump.
7. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
8. Install the oil level indicator tube.
9. Connect the HO2S electrical connector.
10. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .

MATERIAL ITEM SPECIFICATION

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233691-S12465665222006052600000) .
2. Disconnect the crankshaft position (CKP) sensor electrical connector.
3. Disconnect the oxygen sensor (HO2S) electrical connector.
4. Remove the nut and disconnect the wiring harness ground connections.
5. Loosen the bolt and disconnect the powertrain control module (PCM) electrical connector.
6. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector.
7. Disconnect the spark plug wires and position the wires aside.
8. Loosen the nut and disconnect the exhaust gas recirculation (EGR) tube.
9. Remove the three bolts and the exhaust manifold heat shield.
10. Loosen the exhaust manifold-to-catalytic converter bolts.
11. Remove the six exhaust manifold-to-cylinder head bolts.
12. Disconnect the engine wire harness locator.
13. Remove the bolt and separate the catalytic converter heat shield from the cylinder head.
14. Remove the eight cylinder head bolts.
15. Remove the cylinder head.
16. Remove and discard the head gasket.

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1. Using metal surface cleaner, clean the cylinder head sealing surfaces.
2. Check the cylinder head and cylinder block for flatness. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
3. Position a new cylinder head gasket.
4. Position the cylinder head.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate each bolt 90 degrees. Stage 5: Rotate each bolt an additional 90 degrees.
6. Install the catalytic converter heat shield and wire harness ground connection.
7. Position the wiring harness and install the harness locator.
8. Install the exhaust manifold. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
9. Tighten the exhaust manifold-to-catalytic converter bolts.
10. Install the exhaust manifold heat shield.
11. Install the EGR tube.
12. Reposition and connect the spark plug wires.
13. Connect the EVAP canister purge valve electrical connector.
14. Connect the PCM electrical connector.
15. Connect the wire harness ground connections.
16. Connect the HO2S electrical connector.
17. Connect the CKP electrical connector.
18. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233691-S12465665222006052600000) .

MATERIAL ITEM SPECIFICATION

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233691-S12465665222006052600000) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
3. Remove the retainers and the engine anti-roll strut brace.
4. Disconnect the generator electrical connections.
5. Remove the retainers and the generator.
6. Remove the bolt and the drive belt idler pulley.
7. Remove the bolt and the drive belt tensioner pulley.
8. Remove the spark plug wires.
9. Remove the LH exhaust manifold. For additional information, refer to «CYLINDER HEAD LH»(ref-233691-S12885919942006052600000) .
10. Remove the power steering pump and bracket assembly. Disconnect the power steering return hose. Remove the bolt. Remove the two nuts.
11. Remove the eight cylinder head bolts.
12. Remove the cylinder heads.
13. Remove and discard the head gasket.

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1. Using metal surface cleaner, clean the cylinder head sealing surfaces.
2. Check the cylinder head and the cylinder block for flatness. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
3. Position a new cylinder head gasket.
4. Position the cylinder head.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate an additional 90 degrees. Stage 5: Rotate an additional 90 degrees.
6. Install the power steering pump and bracket assembly. Install the bolt. Install the two nuts. Connect the power steering return hose.
7. Install the LH exhaust manifold. For additional information, refer to «CYLINDER HEAD LH»(ref-233691-S12885919942006052600000) .
8. Install the spark plug wires.
9. Install the drive belt tensioner and bolt.
10. Install the drive belt idler pulley and bolt.
11. Install the generator and the retainers.
12. Connect the generator electrical connections.
13. Install the engine anti-roll strut brace and the retainers.
14. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
15. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233691-S12465665222006052600000) .

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1. Disconnect the oil pressure switch electrical connector.
2. Remove the oil pressure switch.
3. To install, reverse the removal procedure.

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
3. Remove the bolts and engine roll restrictor.
4. Remove the bolt, ground strap and nut.
5. Remove the nuts from the front exhaust manifold.
6. Remove the bolt from the rear upper manifold.
7. Remove the nut and disconnect the ground strap electrical connector.
8. Remove the nut and position the heat shield aside.
9. Loosen the rear lower exhaust manifold bolt and position the Y-pipe aside.
10. Remove the bolts and position the starter aside.
11. Remove the bolt and the engine rear plate.
12. Remove the oil pan drain plug and drain the engine oil. Install the drain plug when finished.
13. Remove the 16 bolts and the oil pan.
14. Remove the oil pan gasket from the oil pan.
15. Using metal surface cleaner, clean the oil pan sealing surfaces.

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1. Install the oil pan gasket onto the oil pan.
2. Apply a bead of silicone gasket and sealant in two places where the cylinder block meets the front cover and in two places where the rear main bearing cap meets the cylinder block.
3. Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.
4. Install the engine rear plate and the bolt.
5. Position the starter and install the bolts.
6. Position the Y-pipe and tighten the rear lower exhaust manifold bolt.
7. Position the heat shield and install the nut.
8. Connect the ground strap electrical connector and install the nut.
9. Install the bolt in the rear upper manifold.
10. Install the nuts on the front exhaust manifold.
11. Install the nut, ground strap and bolt.
12. Install the engine roll restrictor and the bolts.
13. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
14. Fill the engine with clean engine oil.
15. Start the engine and check for oil leaks around the oil pan.

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-233691-S12031829252006052600000) .
2. Remove the seven nuts and remove the oil pan baffle.
3. To install, reverse the removal procedure.

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1. Remove the oil pan (6675). For additional information, refer to «OIL PAN»(ref-233691-S12031829252006052600000) .
2. Remove the oil pump (6600). Remove the bolt.
3. Clean all the sealing surfaces.
4. If an internal inspection is required, remove the oil pump cover. Refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) for component testing.
5. To install, reverse the removal procedure.

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1. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F50N»(ref-233690) .
2. Remove the flexplate. Remove the bolts.
3. To install, reverse the removal procedure.

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

MATERIAL ITEM SPECIFICATION

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1. Remove the bolts, flexplate and the spacer.
2. Mount the engine on a suitable engine stand.
3. Remove the drive belt.
4. Remove the retainers and the generator support bracket.
5. Remove the stud bolt and the generator.
6. Remove the bolt and the drive belt idler pulley.
7. Remove the bolt and the drive belt tensioner.
8. Remove the retainers and the support bracket.
9. Remove the retainers and the power steering pump and bracket assembly.
10. Disconnect the A/C high-pressure cutoff switch electrical connector.
11. Disconnect the A/C compressor clutch coil electrical connector.
12. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and separate the connector ends from the bracket.
13. Remove the four bolts and the A/C compressor.
14. Remove the four bolts and the A/C compressor mounting bracket.
15. Remove the four bolts and the coolant pump pulley.
16. Disconnect the crankshaft position sensor (CKP) electrical connector.
17. Disconnect the electrical connector, loosen the two nuts and remove the exhaust gas recirculation (EGR) tube.
18. Disconnect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Detach the harness retainer from the throttle body stud bolt.
19. Remove the upper intake manifold support bracket bolt and nut. Detach the pin-type harness retainer and remove the support bracket.
20. Disconnect the EGR valve vacuum tube.
21. Disconnect the vacuum tube from the fuel supply manifold pressure sensor.
22. Disconnect the vacuum tube from the EGR vacuum regulator solenoid.
23. Disconnect the vacuum tube from the upper intake manifold and remove the vacuum supply harness.
24. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
25. Disconnect the EGR vacuum regulator solenoid and intake manifold runner control (IMRC) electrical connectors. Detach the pin-type harness retainer from the upper intake manifold.
26. Disconnect the positive crankcase ventilation (PCV) tube from the upper intake manifold.
27. Disconnect the PCV tube from the PCV valve and remove the tube.
28. Detach the spark plug wire holder from the valve cover stud and disconnect the radio interference capacitor electrical connector.
29. Remove the bolts and the upper intake manifold.
30. Disconnect the camshaft position (CMP) sensor, engine coolant temperature (ECT) sensor, engine coolant temperature sender and the oil pressure switch electrical connectors.
31. Remove the pin-type retainers and separate the wire harness from the engine.
32. Disconnect the fuel injectors and remove the engine control sensor wiring harness.
33. Disconnect and remove the LH spark plug wires.
34. Remove the nut and the oil level indicator and tube assembly.
35. Remove the six bolts and the LH exhaust manifold.
36. Remove and discard the LH exhaust manifold gasket.
37. Disconnect and remove the RH spark plug wires.
38. Remove the three bolts and the RH exhaust manifold heat shield.
39. Remove the six bolts and the RH exhaust manifold.
40. Remove and discard the RH exhaust manifold gasket.
41. Remove the retainers and the RH valve cover.
42. Remove the retainers and the LH valve cover.
43. Remove the rocker arms and push rods.
44. Remove the eight bolts and the lower intake manifold.
45. Remove and discard the lower intake manifold gaskets.
46. Remove the four bolts and the crankshaft pulley.
47. Remove the crankshaft damper bolt.
48. Remove the crankshaft position (CKP) sensor.
49. Using the special tool, remove the crankshaft damper.
50. Remove the oil filter.
51. Remove the two bolts and the valve tappet guide plate retainer.
52. Remove the valve tappet guide plates.
53. Remove the valve tappets.
54. Remove the screws and the CMP sensor.
55. Remove the camshaft synchronizer bolt.
56. Remove the camshaft synchronizer.
57. Remove the 16 bolts and the oil pan.
58. Remove and discard the oil pan gasket.
59. Remove the bolts and the engine front cover.
60. Remove the engine front cover gasket.
61. Remove the eight bolts and the RH cylinder head.
62. Remove the eight bolts and the LH cylinder head.
63. Remove and discard both cylinder head gaskets.
64. Align the timing marks.
65. Remove the camshaft sprocket bolt.
66. Remove the timing sprockets and the timing chain as an assembly.
67. Remove the bolts and the camshaft thrust plate.
68. Remove the camshaft.
69. If required, remove the camshaft bearings.
70. Remove the bolt and the oil pump.
71. Remove the piston and connecting rod assemblies one at a time. Remove the connecting rod nuts in pairs. Remove the connecting rod cap. Remove the piston and connecting rod assembly.
72. Remove the eight main bearing cap bolts.
73. Remove the main bearing caps.
74. Remove the lower crankshaft main bearings.
75. Remove the crankshaft rear seal.
76. Remove the crankshaft.
77. Remove the upper crankshaft main bearings.
78. Using metal surface cleaner, clean all mating and sealing surfaces.

MATERIAL ITEM SPECIFICATION

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1. Using the special tool, compress the valve spring (6513) and remove the valve spring retainers (6518).
2. Remove the valve springs (6513). For component tests, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
3. Remove the valve seal (6A517).
4. Remove the valve (6507/6505). For component tests, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
5. To assemble, reverse the disassembly procedure. Lubricate the valve stem and the valve seal with clean engine oil.

MATERIAL ITEM SPECIFICATION

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1. Remove the piston rings one at a time starting with the top compression ring and finishing with the lower oil control ring.
2. Using the special tool, press the piston pin (6135) out of the piston and connecting rod assembly.
3. Remove the connecting rod (6205) from the piston (6110).
4. Clean and inspect the piston and the connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .

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1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Using the special tool, press the piston pin into the piston and the connecting rod.
3. Install the second oil control ring.
4. Install the oil control spacer ring.
5. Install the first oil control ring.
6. Install the second compression ring.
7. Install the top compression ring.
8. Check the piston ring end gap and ring-to-groove side clearance. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .

SPECIAL TOOL(S) CHART Piston Ring Compressor 303-D032 (D81L-6002-C) Camshaft Bearing Set 303-017 (T65L-6250-A) Synchronizer Alignment Gauge 303-589 Installer, Crankshaft Vibration Damper 303-175 (T82L-6316-A) Lifting Eyes 303-D030 (D81L-6001-D) or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Heavy Duty Floor Crane 014-00072 or equivalent

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MATERIAL ITEM SPECIFICATION

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1. Install the crankshaft upper main bearings.
2. Position the crankshaft.
3. Install the crankshaft rear seal.
4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
5. Install the crankshaft lower main bearings.
6. Install the main bearing caps.
7. Install the main bearing cap bolts in the sequence shown. Tighten the bolts in pairs. Carry out the crankshaft and crankshaft bearing component tests. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
8. If removed, install new camshaft bearings.
9. Install the camshaft.
10. Install the camshaft thrust plate.
11. Inspect the camshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
12. Align the timing marks.
13. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
14. Install the camshaft sprocket bolt.
15. Install the piston and connecting rod assemblies.
16. Install the connecting rod bearings.
17. Install the connecting rod caps and nuts. Tighten the nuts in pairs.
18. Install the oil pump.
19. Install the valve tappets.
20. Install the valve tappet guide plates.
21. Install the valve tappet guide plate retainer.
22. Install new cylinder head gaskets.
23. Position the cylinder heads.
24. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten the bolts to 50 Nm (37 lb-in). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate 90 degrees. Stage 5: Rotate an additional 90 degrees.
25. Install the oil filter.
26. Align the timing marks.
27. Install a new engine front cover gasket and the engine front cover.
28. Install the engine front cover and water pump assembly. Apply pipe sealant with Teflon® to the bolts indicated. Install the bolts.
29. Apply four beads of gasket maker as shown.
30. Position the oil pan gasket.
31. Position the oil pan and hand-start the bolts.
32. Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.
33. Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
34. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 38 degrees from the centerline of the engine.
35. Install the camshaft synchronizer retaining bolt.
36. Install the camshaft position (CMP) sensor.
37. Apply four beads of silicone gasket and sealant.
38. Position the intake manifold gaskets and end seals.
39. Install the lower intake manifold. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 32 Nm (24 lb-ft).
40. Install the push rods and the rocker arms. Tighten the rocker arm bolts in two stages Stage 1: Tighten the bolts to 10 Nm (89 lb-in). Stage 2: Tighten the bolts to 32 Nm (24 lb-ft).
41. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
42. If removed, install the valve cover gaskets.
43. Install the LH valve cover.
44. Install the RH valve cover.
45. Position a new exhaust manifold gasket and install the RH exhaust manifold.
46. Install the bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
47. Install the RH exhaust manifold heat shield.
48. Position and connect the RH spark plug wires.
49. Position a new exhaust manifold gasket and install the LH exhaust manifold.
50. Install the four bolts and two stud bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
51. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
52. Install the oil level indicator and tube.
53. Position and connect the LH spark plug wires.
54. Position the engine control sensor wiring harness and connect the fuel injector electrical connectors.
55. Position the wire harness along the cylinder block and install the pin-type retainers.
56. Connect the CMP sensor, engine coolant temperature (ECT) sensor, engine coolant temperature sender and the oil pressure switch electrical connectors.
57. Install the upper intake manifold. Tighten bolts in two stages in the sequence shown. Stage 1: Tighten the bolts hand tight. Stage 2: Tighten the bolts to 10 Nm (89 lb-in).
58. Attach the spark plug wire holder from the valve cover stud and connect the radio interference capacitor electrical connector.
59. Connect the positive crankcase ventilation (PCV) tube to the PCV valve.
60. Connect the PCV tube to the upper intake manifold.
61. Connect the vacuum regulator solenoid and intake manifold runner control (IMRC) electrical connectors. Attach the pin-type harness retainer to the upper intake manifold.
62. Connect the RH heated oxygen sensor (HO2S) electrical connector.
63. Connect the vacuum tube to the upper intake manifold.
64. Connect the vacuum tube to the EGR vacuum regulator solenoid.
65. Connect the vacuum tube to the fuel supply manifold pressure sensor.
66. Connect the EGR valve vacuum hose.
67. Position the upper intake manifold support bracket and install bolt and nut. Attach the pin-type harness retainer to the bracket.
68. Connect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Detach the harness retainer from the throttle body stud bolt.
69. Install the EGR tube. Connect the electrical connector. Tighten the two EGR tube nuts.
70. Using the special tool, install the crankshaft damper.
71. Install the crankshaft damper bolt and the washer.
72. Install the crankshaft pulley and the bolts.
73. Install the crankshaft position (CKP) sensor.
74. Connect the CKP sensor electrical connector.
75. Install the coolant pump pulley.
76. Install the A/C compressor mounting bracket.
77. Install the A/C compressor.
78. Install the wiring harness connectors on the bracket and connect the HO2S electrical connector.
79. Connect the A/C compressor clutch coil electrical connector.
80. Connect the A/C high pressure cutoff switch electrical connector.
81. Install the power steering pump and bracket assembly.
82. Install the support bracket.
83. Install the drive belt tensioner.
84. Install the drive belt idler pulley.
85. Install the generator stud bolt.
86. Install the generator support bracket.
87. Install the drive belt.
88. Install the spacer, flexplate and the bolts. Tighten the bolts in a criss-cross pattern.
89. Remove the engine from the stand.

SPECIAL TOOL(S) CHART Powertrain Lift with Tilting Plate 014-00765 or equivalent Lifting Eyes 303-D030 (D81L-6001-D) or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Heavy Duty Floor Crane 014-00072 or equivalent Teflon® Seal Replacer Set 211-D027 (D90P-3517-A) or equivalent

MATERIAL ITEM SPECIFICATION

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

1. Position the engine on the subframe and transmission assembly.
2. Install the 5 transmission-to-engine bolts and 1 stud bolt. Tighten to 50 Nm (37 lb-ft).
3. Connect the lower radiator hose to the coolant pump.
4. Install the dual converter Y-pipe, 2 bolts and 2 nuts. Tighten to 40 Nm (30 lb-ft).
5. Connect the catalyst monitor sensor electrical connector.
6. Connect the catalyst monitor sensor electrical connector.
7. Install the RH engine support insulator through bolt. Tighten to 120 Nm (89 lb-ft).
8. Install the heat shield nut. Tighten to 20 Nm (15 lb-ft).
9. Install the LH engine support insulator-to-subframe nut. Tighten to 90 Nm (66 lb-ft).
10. Install the 2 RH engine support insulator bracket-to-transmission bolts. Tighten to 60 Nm (44 lb-ft).
11. Using the special tools, secure the engine to the powertrain lift.
12. Install the heat shield and the 2 nuts. Tighten to 20 Nm (15 lb-ft).
13. Position the 42-pin connector on the bracket and connect the transaxle harness electrical connector.
14. Connect the turbine shaft speed (TSS) sensor electrical connector.
15. Connect the output shaft speed sensor (OSS) electrical connector.
16. Install the ignition coil and 3 bolts. Tighten to 6 Nm (53 lb-in)
17. Connect the ignition coil electrical connector.
18. Connect the spark plug wires to the ignition coil.
19. Using the special tool, install a new seal on the power steering pressure (PSP) tube fitting.
20. Connect the PSP tube to the power steering pump. Tighten to 48 Nm (35 lb-ft).
21. Install the PSP tube bracket and the nut. Tighten to 27 Nm (20 lb-ft).
22. Install the PSP tube bracket and the nut. Tighten to 27 Nm (20 lb-ft).
23. Using the special tool, raise the engine, transmission and subframe into the vehicle.
24. Install the 4 front subframe-to-body bolts. Tighten to 103 Nm (76 lb-ft).
25. Connect the LH and RH tie-rod ends to the steering knuckles and install the nuts. Tighten to 55 Nm (41 lb-ft). Install the cotter pins.
26. Connect the LH and RH stabilizer links to the stabilizer bar and install the nuts. Tighten to 55 Nm (41 lb-ft).
27. Install the 4 torque converter nuts. Tighten to 36 Nm (27 lb-ft).
28. Install the engine rear plate and the bolt. Tighten to 12 Nm (9 lb-ft).
29. Install the starter motor and the 2 bolts. Install the 2 bolts hand-tight, then tighten the top bolt followed by the lower bolt. Tighten to 25 Nm (18 lb-ft).
30. Connect the starter motor electrical connectors. Tighten to 12 Nm (9 lb-ft).
31. Install the starter motor electrical connector cover.
32. Connect the auxiliary oil cooler assembly. If equipped, connect the transmission oil cooler hose. Connect the power steering return hose.
33. If equipped, connect the wiring harness electrical connector.
34. Connect the transmission oil cooler hose.
35. Connect the lower radiator hose to the radiator and the degas bottle supply hose.
36. Install the radiator support bracket and the 4 bolts. Tighten to 10 Nm (89 lb-in).
37. Connect the A/C discharge tube. Tighten to 10 Nm (89 lb-in).
38. Connect the catalytic converter to the muffler pipe and install the muffler pipe clamp. Hand tighten the 2 muffler pipe clamp nuts.
39. Connect the catalytic converter to the muffler pipe and the dual converter Y-pipe and install the nuts. Tighten to 40 Nm (30 lb-ft). Tighten the 2 muffler pipe clamp nuts to 40 Nm (30 lb-ft).
40. Connect the powertrain control module (PCM) electrical connector. Tighten to 4 Nm (35 lb-in).
41. Install the ground wire terminal and the bolt. Tighten to 20 Nm (15 lb-ft).
42. Connect the evaporative emissions (EVAP) canister purge valve electrical connector.
43. Connect the ground wire electrical terminals and install the bolt. Tighten to 10 Nm (89 lb-in).
44. Connect the heater hose.
45. Install the engine roll restrictor and the 2 bolts. Tighten to 48 Nm (35 lb-ft).
46. Connect the degas bottle hose.
47. Connect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
48. Connect the A/C suction tube to the accumulator drier. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233738) .
49. Connect the generator electrical connections. Tighten to 8 Nm (71 lb-in).
50. Connect the power steering return hose.
51. Connect the upper radiator hose and heater hose to the thermostat housing.
52. Connect the ground wire and install the nut. Tighten to 25 Nm (18 lb-ft).
53. Connect the mass air flow (MAF) sensor electrical connector.
54. Connect the transmission range (TR) sensor and the 42-pin electrical connectors. Tighten to 10 Nm (89 lb-in).
55. Install the manual control lever cable in the bracket.
56. Connect the manual control lever cable to the manual control lever and install the nut. Tighten to 17 Nm (13 lb-ft).
57. Connect the vacuum hose and the EVAP return tube.
58. Position the accelerator cable and bracket and install the 2 bolts. Tighten to 9 Nm (80 lb-in).
59. Connect the accelerator cable, speed control cable and throttle return spring.
60. Install the accelerator control splash shield and the 2 retainers.
61. Connect the steering column to the steering gear input shaft and install the bolt. Tighten to 25 Nm (18 lb-ft).
62. Position the steering column input shaft coupling boot and install the 3 nuts. Tighten to 6 Nm (53 lb-in).
63. Install the RH cowl extension panel and the 3 screws (2 shown).
64. Install the clip on the RH cowl extension panel.
65. Install the RH cowl panel grille and the 3 retaining clips (2 shown).
66. Install the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-233693) .
67. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233699) .
68. Fill the engine with clean engine oil.
69. Install the battery and connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
70. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-233712) .
71. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233700) .
72. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233738) .