Engine - 3.0L (4V): Other Ford Taurus IV рестайлинг

Material

MATERIAL 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 LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) .
4. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
5. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-233694) .
6. Remove the retaining nut and position the power steering pressure line and muffler out of the way.
7. Remove the upper retaining bolts from the generator.
8. Remove the bolts, nuts and the engine-to-transaxle bracket.
9. Remove the torque converter inspection cover.
10. Remove the front pin-type retainers and position the front rocker panel moulding aside.
11. Remove the rear portion of the front fender splash shield. Remove the screws and the pin-type retainers.
12. Remove the two screws and the generator splash shield.
13. Install the special tool.
14. Remove the crankshaft damper pulley.
15. Remove the crankshaft damper bolt and washer.
16. Using the special tool, remove the crankshaft damper.
17. Disconnect the crankshaft position (CKP) sensor electrical connector. Remove the bolt and the CKP sensor.
18. Remove the generator bolt and position the generator to gain access to the electrical connector and terminal nut.
19. Disconnect the generator electrical connectors. Remove the nut and the B+ wire terminal. Disconnect the generator electrical connector.
20. Remove the bolts and the A/C compressor to front cover bracket.
21. Disconnect the camshaft position (CMP) sensor electrical connector. Remove the bolt and remove the CMP sensor.
22. Remove the tie strap from the power steering hose.
23. Remove the retaining nut and position the A/C low-pressure hose out of the way.
24. Remove the bolts and position the A/C high-pressure hose on top of the belt tensioner.
25. Remove the bolt and remove the belt tensioner.
26. Disconnect the engine cooling fan electrical connector and unclip the wiring harness.
27. Remove the bolt and the engine cooling fan.
28. Install the special tools to support the engine.
29. Remove the two upper A/C compressor bolts.
30. Remove the two lower A/C compressor bolts and position the A/C compressor aside.
31. Remove the bolts from the A/C bracket.
32. Raise the engine away from the A/C bracket using the engine support tool.
33. Remove the two oil pan-to-front cover bolts.
34. Remove the bolts, studs and the engine front cover.

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1. Clean all sealing surfaces with metal surface cleaner.
2. Install three new gaskets in the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
4. Position the cover and install the bolts in the sequence shown.
5. Install the two oil pan-to-front cover bolts.
6. Remove the oil pan plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
7. Using the engine support tool, lower the engine back together with the A/C bracket.
8. Install the bolts. Tighten the bolts in two stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten an additional 90 degrees.
9. Position the A/C compressor and install the two lower bolts.
10. Install the two upper A/C compressor bolts.
11. Position the engine cooling fan and install the bolt.
12. Connect the engine cooling fan electrical connector and clip the wiring harness.
13. Position the belt tensioner and install the bolt.
14. Position the A/C high-pressure hose and install the bolts.
15. Position the A/C low-pressure hose and install the retaining nut.
16. Install the tie strap to the power steering hose.
17. Install the CMP sensor and install the bolt. Connect the CMP sensor electrical connector.
18. Position the A/C compressor to front cover bracket and install the bolts.
19. Connect the generator. Install the B+ wire terminal and nut. Connect the generator electrical connector.
20. Install the generator and the lower bolt.
21. Install the CKP sensor. Connect the CKP sensor electrical connector.
22. Install the generator upper bolts.
23. Reposition the power steering line and muffler and install the retaining nut.
24. Tighten the generator lower bolt.
25. Install the special tool.
26. Apply silicone gasket and sealant to the end of the keyway slot.
27. Using the special tool, install the crankshaft damper.
28. Install the bolt and washer and tighten in four stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten 90 degrees.
29. Install the crankshaft pulley.
30. Install the generator splash shield and the two screws.
31. Install the rear portion of the front fender splash shield. Install the screws and the pin-type retainers.
32. Position the front rocker panel moulding and install the pin-type retainers.
33. Install the torque converter inspection cover.
34. Position the engine-to-transaxle bracket and install the nuts and bolts.
35. Install the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
36. Install the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) .
37. Fill the engine with clean engine oil.
38. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
39. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-233694) .

MATERIAL SPECIFICATION

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Scheme 559

1. Disconnect the crankcase ventilation tube from the air cleaner outlet pipe.
2. Remove the nuts and the coolant pump drive belt cover.
3. Disconnect coil-on-plug electrical connectors. Detach the retainer and position the wiring harness aside.
4. Remove the bolts and the ignition coils.
5. Disconnect the wiring harness from the valve cover studs. Position the wiring harness aside.
6. Remove the stud bolts and the valve cover. Remove and discard the gasket.

Scheme 560

1. Tighten the valve cover studs in the sequence shown.
2. Connect the wiring harness to the valve cover studs.
3. Install the bolts and the ignition coils.
4. Position the wiring harness and retainer, and connect the coil-on-plug electrical connectors.
5. Install the coolant pump drive belt cover and the nuts.

MATERIAL SPECIFICATION

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1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .
2. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
3. Disconnect the coil-on-plug electrical connectors. Detach the wiring harness retainers and position the wiring harness aside.
4. Detach the wiring harness retainer from the stud.
5. Detach the pin-type retainer.
6. Remove the nuts from the valve cover studs. Position the radio interference capacitor and wiring harness conduit aside.
7. Remove the differential pressure feedback EGR sensor tube and bracket. Detach the electrical connector pin-type retainer. Remove the bolts from the differential pressure feedback EGR bracket. Disconnect and remove differential pressure feedback EGR and bracket from the vacuum tubes.
8. Remove the bolts and the ignition coils.
9. Remove the studs and the valve cover. Remove and discard the gaskets.

Scheme 569

Scheme 570

1. Tighten the valve cover studs in the sequence shown.
2. Install the bolts and the ignition coils.
3. Install the differential pressure feedback EGR valve sensor and bracket. Connect the differential pressure feedback EGR valve tube and bracket to the vacuum tubes. Install the differential pressure feedback EGR sensor and bracket and install the bolts. Attach the HO2S electrical connector pin-type retainer.
4. Connect the differential pressure feedback EGR sensor and the RH heated HO2S electrical connectors.
5. Position the radio interference capacitor and wiring harness conduit and install the nuts.
6. Attach the pin-type retainer.
7. Attach the wiring harness retainer to the stud.
8. Attach the wiring harness retainers and connect the coil-on-plug electrical connectors.
9. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233692-S35322932072006052600000) .

MATERIAL SPECIFICATION

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Scheme 573

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
2. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
3. Using the special tools, remove the coolant pump drive pulley and discard.
4. Using the special tools, remove the camshaft oil seal and discard.
5. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
6. Loosen the bolts for the LH camshaft thrust caps.
7. Loosen the LH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
8. Remove the camshafts.

Scheme 574

Scheme 575

1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install a new press-in-place gasket and install the camshaft oil seal retainer.
7. Install the new camshaft oil seal. Using the special tools positioned over the oil seal, turn to install the seal.
8. Using the special tool, install the coolant pump drive pulley.
9. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233714) .
10. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .

MATERIAL SPECIFICATION

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Scheme 577

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
2. Loosen the RH camshaft thrust cap bolts.
3. Loosen the RH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
4. Remove the camshafts.

Scheme 578

Scheme 579

1. Lubricate camshafts with engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with engine oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Verify that the camshaft bearing caps are in the correct locations.
5. Tighten the bolts in the sequence shown.
6. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .

MATERIAL SPECIFICATION

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Scheme 581

1. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-233692-S01653174612006052600000) and «VALVE COVER RH»(ref-233692-S32098761522006052600000) .
2. Remove the LH and RH spark plugs.
3. Remover the RH front wheel. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
4. Remove the screws, the pin-type retainers, and the RH front inner fender splash shield.
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower.
6. Using the special tool, remove the follower.
7. To install, reverse the removal procedure. Lubricate the camshaft followers with clean engine oil.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 582

1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT VIBRATION DAMPER»(ref-233692-S18033234982006052600000) .
2. Using the special tool, remove the crankshaft front oil seal and discard.

Scheme 583

1. Apply clean engine oil to the seal before installing the seal.
2. Using the special tool, install the crankshaft front oil seal.
3. Install the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT VIBRATION DAMPER»(ref-233692-S18033234982006052600000) .

MATERIAL 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. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
3. Remove the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .
4. Remove the LH exhaust manifold-to-pipe nuts.
5. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-233700) .
6. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
7. Remove the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-233692-S21749774132006052600000) .
8. Using the special tools, lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
9. Remove the three-bar engine support.
10. Remove the camshaft followers.
11. Remove the hydraulic lash adjusters.
12. Disconnect the LH heated oxygen sensor (HO2S) electronic connector.
13. Remove the nuts in the sequence shown and remove the LH exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.
14. Remove the oil level indicator.
15. Remove the nut and the oil level indicator tube. Inspect and, if necessary, install a new O-ring seal.
16. Remove the LH cylinder block drain plug.
17. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
18. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.

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Scheme 590

1. Position the LH cylinder head, gasket and install the bolts in the sequence shown in six stages. Tighten the bolts in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Install the LH cylinder block drain plug.
3. Install the oil level indicator tube and the nut.
4. Install the new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
5. Install the new LH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
6. Connect the LH HO2S electrical connector.
7. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
8. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
9. Install the three-bar engine support.
10. Remove the four A/C compressor bracket bolts.
11. Using the special tools, raise the engine away from the A/C compressor bracket.
12. Install the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-233692-S21749774132006052600000) .
13. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
14. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-233700) .
15. Install the LH exhaust manifold-to-pipe nuts.
16. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .

MATERIAL 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. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
3. Remove the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .
4. Remove the rear support brace. Remove the bolt. Remove the nut. Remove the rear support brace.
5. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
6. Remove the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-233692-S23586958042006052600000) .
7. Using the special tools, lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
8. Remove the three-bar engine support.
9. Remove the RH exhaust manifold-to-pipe bolts.
10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
11. Remove the bolt and the ground wire.
12. Remove the camshaft followers.
13. Remove the hydraulic lash adjusters.
14. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
15. Remove the nuts in the sequence shown and remove the RH exhaust manifold. Remove the studs. Discard the gasket, studs and nuts.
16. Remove the RH cylinder block drain plug.
17. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
18. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.

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1. Position the RH cylinder head, gasket and install the bolts in the sequence shown in six stages. Tighten the bolts in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Install the RH cylinder block drain plug.
3. Install the new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
4. Install the new RH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
5. Connect the RH HO2S electrical connector.
6. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
7. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
8. Install the ground wire and bolt.
9. Connect the EGR tube to the exhaust manifold.
10. Install the RH exhaust manifold-to-pipe bolts.
11. Install the three-bar engine support.
12. Remove the four A/C compressor bracket bolts.
13. Using the special tools, raise the engine away from the A/C compressor bracket.
14. Install the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-233692-S23586958042006052600000) .
15. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233692-S34132369242006052600000) .
16. Install the rear support brace. Install the rear support brace. Install the bolt. Install the nut.
17. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233700) .

MATERIAL SPECIFICATION

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Scheme 604

1. Remove the oil level indicator.
2. Remove the oil level indicator tube. Remove the stud. Remove the oil level indicator tube.
3. Inspect the O-ring seal at the end of the oil level indicator tube and install a new O-ring seal if necessary.
4. To install, reverse the removal procedure. Lubricate the O-ring seal with clean engine oil.

MATERIAL SPECIFICATION

Scheme 605

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-233684) .
2. Remove the RH front inner wheel splash shield. Remove the screws and the pin-type retainer.
3. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
4. Secure the exhaust system and remove the jackstand.
5. Drain the engine oil.
6. Install and tighten the drain plug to 27 Nm (20 lb-ft).
7. Remove and discard the oil filter.
8. Remove the bolts, nuts and the engine-to-transaxle bracket.
9. Remove the torque converter inspection cover.
10. Remove the 18 bolts and the oil pan.

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Scheme 609

1. Clean all sealing surfaces on the engine and the oil pan with metal surface cleaner.
2. Install a new gasket on the oil pan.
3. Apply a 10 mm (0.40 in) diameter dot of silicone gasket and sealant to the areas indicated.
4. Position the oil pan and hand tighten the oil pan-to-transaxle bolts.
5. Tighten the oil pan bolts in the sequence shown.
6. Tighten the oil pan-to-transaxle bolts.
7. Install the torque converter inspection cover.
8. Position the engine-to-transaxle bracket and install the nuts and the bolt.
9. Lubricate the oil filter O-ring with clean engine oil and install the new oil filter.
10. Position a jackstand and release the exhaust system.
11. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
12. Install the RH front inner wheel splash shield. Install the screws and the pin-type retainer.
13. Install the LH exhaust manifold-to-pipe nuts.
14. Fill the crankcase with clean engine oil.

MATERIAL SPECIFICATION

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Scheme 611

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-233692-S41519185732006052600000) .
2. Remove the nut, bolts and the oil pump screen and pick-up tube.
3. Remove and discard the O-ring seal.

Scheme 612

1. Install the O-ring seal and lubricate with clean engine oil.
2. Install the oil pump screen cover and tube. Position the oil pump screen and pick-up tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten 45 degrees.
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-233692-S41519185732006052600000) .

Scheme 613

1. Remove the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-233692-S09936937992006052600000) .
2. Remove the nuts and the oil pan baffle.

MATERIAL SPECIFICATION

Scheme 614

Scheme 615

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
2. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
3. Drain the engine oil. Install a new drain plug gasket and tighten the drain plug to 27 Nm (20 lb-ft).
4. Remove the 18 bolts and the oil pan.
5. Remove the nut, bolts and the oil pump screen and pick-up tube.
6. Remove and inspect the O-ring seal.
7. Remove the bolts in the indicated sequence and remove the oil pump.

Scheme 616

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Scheme 619

1. Position the oil pump and install the bolts in the sequence shown.
2. Install the O-ring seal.
3. Install the oil pump screen and pick-up tube. Position the oil pump screen and pick-up tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
4. Clean all sealing surfaces on the engine and on the oil pan with metal surface cleaner.
5. Position a new gasket on the oil pan.
6. Apply a 10 mm (0.40 in) diameter dot of silicone gasket and sealer to the areas indicated.
7. Position the oil pan and hand-tighten the oil pan-to-transaxle bolts.
8. Tighten the oil pan bolts in the sequence shown.
9. Tighten the oil pan to transaxle bolts.
10. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-233702) .
11. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233692-S22647073652006052600000) .
12. Fill the crankcase to the correct level with clean motor oil.

Scheme 620

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

MATERIAL SPECIFICATION

Scheme 621

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-233692-S13747979262006052600000) .
2. Using the special tools, remove the crankshaft rear oil seal and discard.

MATERIAL SPECIFICATION

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1. Remove the top compression ring.
2. Remove the second compression ring.
3. Remove the first oil control ring.
4. Remove the oil control spacer ring.
5. Remove the second oil control ring.
6. Remove the clips.
7. Remove the piston pin and the connecting rod from the piston.
8. Clean and inspect the connecting rod and the piston. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .

Scheme 629

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Scheme 633

1. Lubricate the piston pin and piston bore with clean engine oil and install the piston pin.
2. Install the clips.
3. Check the piston ring end gap. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233705) .
4. Lubricate the piston rings with clean engine oil.
5. Install the first oil control ring.
6. Install the oil control spacer ring.
7. Install the second oil control ring.
8. Install the second compression ring. The top of the second compression ring has a "0" on it. Position this side of the ring towards the top of the piston.
9. Install the top compression ring. The top compression ring can be installed with either side up.

MATERIAL SPECIFICATION

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Scheme 666

1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. If removed, install the crankshaft key into the keyway on the crankshaft.
3. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block rear face. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2. The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
4. Using the chart (Scheme 650), choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. For example: If the block code is * 0609 * 0711 * and the crankshaft code is * 8580 * 8082 *, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
5. Install the main bearings into the cylinder block.
6. Install the main bearings into the lower cylinder block.
7. Install the crankshaft thrust bearing.
8. If removed, install the crankshaft key.
9. Apply clean engine oil to the crankshaft main and rod bearing journals.
10. Apply gasket and sealant to the cylinder block as shown.
11. Position the crankshaft in the cylinder block.
12. Position the lower cylinder block and install the bolts and studs. Tighten the bolts and studs in the sequence shown in four stages. Stage 1: Tighten fasteners 1--8 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 9--16 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 1--16 90 degrees. Stage 4: Tighten fasteners 17-22 to 25 Nm (18 lb-ft).
13. Using the special tool, measure crankshaft end play.
14. Using the special tools, install the crankshaft rear oil seal.
15. Position the flexplate and loosely install the bolts. Install the special tool to hold the flexplate.
16. Tighten the flexplate bolts.
17. Mount the engine on an engine stand.
18. Using the special tools, install the piston and connecting rod assemblies.
19. Install the connecting rod caps and bolts. Tighten the bolts in two stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft).
20. Fill the oil pump with clean engine oil. Rotate the oil pump one revolution. Drain the engine oil.
21. Position the oil pump and install the bolts in the indicated sequence.
22. Position the oil pan baffle and install the nuts. Tighten the nuts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten 45 degrees.
23. Install a new O-ring seal on the oil pump screen and pick-up tube and lubricate with clean engine oil.
24. Install the oil pump screen and pick-up tube. Position the oil pump screen and pick-up tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten 45 degrees.
25. Install the crankcase cover, a new gasket and the bolts.
26. Position the LH and RH cylinder heads and new gaskets. Install the bolts. Tighten the bolts in the sequence shown in six stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
28. Apply clean engine oil to the LH and RH camshaft followers.
29. Install the LH and RH camshaft followers.
30. Apply clean engine oil to the LH and RH camshafts.
31. Install the LH and RH camshafts. Locate the camshafts as shown.
32. Position the RH camshaft caps and install the bolts in the sequence shown.
33. Position the LH camshaft caps and install the bolts in the sequence shown.
34. Verify that the camshaft bearing caps are in the correct locations.
35. Install a new press-in-place gasket and install the camshaft oil seal retainer.
36. Install a new camshaft oil seal. Using the special tools positioned over the oil seal, turn to install the seal.
37. Using the special tool, install the coolant pump drive pulley.
38. Remove the crankshaft damper bolt.
39. Install the crankshaft sprockets with the timing marks facing outward.
40. Position the chain tensioner in a soft-jawed vise.
41. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
42. Slowly compress the timing chain tensioner.
43. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
44. If the timing marks on the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and the RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42. Mark the link.
45. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
46. Install the LH timing chain tensioner and the tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
47. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
48. Verify that the RH camshafts are correctly positioned.
49. Install the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
50. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
51. Remove the LH and RH timing chain tensioner piston retaining wires.
52. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
53. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
54. Remove the crankshaft damper bolt.
55. Install the ignition pulse wheel.
56. Install the LH and RH spark plugs.
57. Install new gaskets in the front cover.
58. Apply a 6 mm (0.24 in) dot of gasket and sealant to the cylinder block-to-lower cylinder block and the cylinder head mating surfaces.
59. Position the front cover and install the bolts and studs in the sequence shown.
60. Using the special tool, install the crankshaft front oil seal.
61. Install the coolant tube, the bolt and the stud.
62. Install the oil pressure sensor.
63. Install a new seal on the oil level indicator tube and apply clean engine oil.
64. Install the oil level indicator tube and install the bolt.
65. Apply clean engine oil to the oil filter O-ring and install a new oil filter.
66. Apply gasket and sealant to the end of the crankshaft damper keyway slot.
67. Using the special tool, install the crankshaft vibration damper.
68. Install the special tool to hold the flexplate.
69. Install the crankshaft vibration damper washer and bolt. Tighten the bolt in four stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten to 90 Nm (66 lb-ft).
70. Install the crankshaft pulley.
71. Install new gaskets in the valve covers.
72. Apply a 8 mm (0.31 in) dot of gasket and sealant at the cylinder block-to-front cover mating surface of the LH and RH valve covers.
73. Position the RH valve cover and install the studs in the sequence shown.
74. Position the LH valve cover and install the studs in the sequence shown.
75. Install the coolant pump. Position the coolant pump and install the mounting bolts. Tighten the bolts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 90 degrees.
76. Install the heater hose assembly and connect the heater hose to the coolant pump.
77. Connect the coolant pump outlet hose.
78. Connect the engine coolant temperature (ECT) sensor electrical connector and attach the pin-type retainer.
79. Rotate the drive belt tensioner clockwise and install the coolant pump belt.
80. Install the belt on the coolant pump pulley and position it on the camshaft pulley.
81. Rotate the crankshaft clockwise to seat the belt on the camshaft pulley.
82. Install the coolant pump drive belt cover and nuts.
83. Install the coolant tube assembly and connect the two hose clamps.
84. Install the new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
85. Install the new RH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
86. Install the new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
87. Install the new LH exhaust manifold gasket, the exhaust manifold and the new nuts. Tighten the nuts in the sequence shown.
88. Position the radio interference capacitor and wiring harness conduit and install the nuts.
89. Attach the pin-type retainer.
90. Attach the wiring harness retainer to the stud.
91. Install new gaskets in the lower intake manifold.
92. Position the lower intake manifold and install the bolts in the sequence shown.
93. Connect the fuel injector electrical connectors.
94. Connect the fuel injection pressure and temperature sensor vacuum tube and electrical connector.
95. Install the RH and LH ignition coils and the bolts.
96. Connect the LH heated oxygen sensor (HO2S) electrical connector.
97. Position the knock sensor (KS) and install the bolt.
98. Connect the KS electrical connector.
99. Install the differential pressure feedback EGR sensor and bracket. Connect the differential pressure feedback EGR sensor to the vacuum tubes. Position the differential pressure feedback EGR sensor and bracket and install the bolts. Attach the HO2S electrical connector pin-type retainer.
100. Connect the differential pressure feedback EGR sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
101. Connect the coil-on-plug electrical connectors and attach the wiring harness retainers.
102. Install new gaskets in the upper intake manifold, if required.
103. Position the upper intake manifold and install the bolts in the sequence shown.
104. Connect the EGR vacuum regulator solenoid electrical connector.
105. Connect the hose from the positive crankcase ventilation (PCV) valve.
106. Connect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
107. Connect the EGR tube to the exhaust manifold.
108. Install the crankshaft position (CKP) sensor. Install the sensor. Install the bolt. Connect the electrical connector and clip into place.
109. Connect the oil pressure sensor electrical connector.
110. Connect the harness to the front LH valve cover studs.
111. Connect the camshaft position (CMP) sensor electrical connector.
112. Position the A/C compressor bracket and install the bolts. Tighten the bolts in two stages. Stage 1: Tighten bolts 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten bolts 1 through 4 an additional 90 degrees.
113. Position the A/C compressor and install the bolts.
114. Connect the A/C compressor. Connect the compressor electrical connector. Connect the pressure sensor electrical connector. Connect the harness to the bracket.
115. Position the power steering pump and install the bolts.
116. Install the generator. Position the generator. Install the studs. Install the bolt. Connect the electrical connector.
117. Rotate the tensioner and install the accessory drive belt.
118. Install the special tool.
119. Using the special tools and a suitable engine hoist, remove the engine from the stand.

MATERIAL SPECIFICATION

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

1. Using the special tools and a suitable engine hoist, support the engine and assemble with the transaxle.
2. Install the five engine-to-transaxle bolts.
3. Connect the coolant hose quick connect fitting.
4. Connect the coolant hose to the throttle body.
5. Connect the transaxle electrical connector.
6. Connect the output shaft speed (OSS) sensor electrical connector.
7. Connect the turbine shaft speed (TSS) sensor electrical connector.
8. Connect the heater hose to the coolant pump.
9. Install the LH engine mount nut.
10. Install the RH engine mount nut.
11. Using the special tool, install new seals on the power steering hose fitting.
12. Connect the power steering pressure line and install the clamp bolt.
13. Install the engine support brace.
14. Position the coolant tube to the head and install the coolant tube mounting bolt.
15. Install the coolant tube lower mounting bolt.
16. Using the special tool, raise the engine/transaxle assembly into the vehicle and loosely install the four subframe bolts.
17. Align the subframe with the body. Install a 19 mm (0.75 in) rod into the front LH subframe-to-body alignment hole. Hand-tighten the bolt.
18. Align the subframe with the body. Install a 19 mm (0.75 in) rod into the front RH subframe-to-body alignment hole. Hand-tighten the bolt.
19. Verify the subframe-to-body alignment at both of the alignment holes.
20. Tighten the four subframe bolts.
21. Apply a 10 mm (0.4 in) dot of silicone gasket and sealant to the front cover-to-cylinder block mating surface.
22. Install a new gasket, position the oil pan and loosely install the bolts and the studs in the indicated sequence.
23. Install the oil pan to transaxle housing bolts.
24. Tighten the oil pan bolts and studs in the sequence shown.
25. Position the engine-to-transaxle bracket and install the nuts and the bolt.
26. Install the four torque converter-to-flexplate nuts.
27. Install the torque converter inspection cover.
28. Install the splash shield and the pin-type retainers.
29. Clip the engine block heater harness to the engine block.
30. If equipped, connect the engine block heater electrical connector.
31. If equipped, connect the lower radiator hose and reservoir supply hose.
32. Install the radiator support bracket and bolts.
33. Connect the A/C high pressure tube to the condenser and install the nut.
34. Connect the transaxle cooler hose.
35. Connect the power steering and transaxle hoses to the cooler.
36. Connect the RH and LH tie-rod ends. Install the nut. Install the cotter pin.
37. Install the RH and LH sway bar end link nuts.
38. Position the starter motor ground cable and install the nut.
39. Position the starter cable and install the nut.
40. Install the starter cable cover.
41. Position the inner fender splash shield and install the pin-type retainers.
42. Position the dual converter Y-pipe and install the nut.
43. Install the nuts.
44. Install the RH exhaust manifold-to-pipe bolts.
45. Install the two LH exhaust manifold-to-pipe nuts.
46. Connect the catalyst monitor sensor (CMS) electrical connectors.
47. Connect the power steering fluid hose to the reservoir.
48. Connect the upper radiator hose.
49. Install the generator wiring, pin-type retainer and nut.
50. Connect the coolant recovery bottle hose.
51. Install the heater hose bracket nut.
52. Connect the heater hoses.
53. Install the heater hose bracket nut.
54. Connect the low pressure A/C tube spring lock coupling at the accumulator/drier. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233738) .
55. Connect the harness and tighten the bolt.
56. Clip the shifter cable to the bracket and install the nut.
57. Connect the transaxle range (TR) sensor electrical connector.
58. Install the accelerator and cruise control cables in the bracket. Connect the cables and the throttle return spring.
59. Position the accelerator cable splash shield and install the pin-type retainers.
60. Connect the evaporative emission (EVAP) system hoses.
61. Connect the brake booster vacuum hose.
62. Connect the powertrain control module (PCM) electrical connector and tighten the bolt.
63. If equipped, position the roll restrictor bracket and the bolts.
64. Position the ground strap and install the bolt.
65. Install the steering shaft pinch bolt.
66. Install the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-233693) .
67. Install the RH water shield and the three (two shown) screws.
68. Install the clip on the water shield.
69. Install the RH cowl panel and three (two shown) clips.
70. Connect the fuel rail supply tube. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233735) .
71. Install the air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233699) .
72. Fill the engine with clean engine oil.
73. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233724) .
74. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-233700) .
75. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-233712) .
76. Evacuate, leak test, and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233738) .