Engine - 3.0L (2V): Removal & Installation Ford Taurus IV facelift

Installation

1. Using crankshaft vibration damper replacer, install the crankshaft oil seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-212098-S36512369942005122300000) .

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1. Drain the engine coolant. For additional information, refer to «ENGINE - 3.0L (4V)»(ref-212099) .
2. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
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 - 3.0L (4V)»(ref-212099) .
6. Loosen the four water pump pulley bolts.
7. Remove the crankshaft damper (6316). For additional information, refer to «CRANKSHAFT PULLEY»(ref-212098-S36512369942005122300000) .
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-212098-S21382295482005122300000) .
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 & HOISTING»(ref-163061-S26137620762004061700000) .
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-212098-S21382295482005122300000) .
15. Install the crankshaft damper. For additional information, refer to «CRANKSHAFT PULLEY»(ref-212098-S36512369942005122300000) .
16. Install the coolant expansion tank. For additional information, refer to «ENGINE - 3.0L (4V)»(ref-212099) .
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 «GENERAL PROCEDURES»(ref-212100-S15354658682005122300000) .

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1. Remove the LH and the RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-212098-S41708833182005122300000) and «VALVE COVER RH»(ref-212098-S24575411302005122300000) .
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).

Removal and Installation

1. Remove the rocker arms. For additional information, refer to «ROCKER ARM»(ref-212098-S19794006122005122300000) .
2. Remove the push rods.
3. To install, reverse the removal procedure.

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1. Remove the rocker arms. For additional information, refer to «ROCKER ARM»(ref-212098-S19794006122005122300000) .
2. Rotate the crankshaft until the piston for the valve being worked on is at the top of its stroke with both the intake valve and the exhaust valve closed.
3. Hold the valve in the cylinder head. Remove the spark plug. For additional information, refer to «ENGINE IGNITION - 3.0L (2V)»(ref-212103) . Apply a minimum of 689 kPa (100 psi) of compressed air to the cylinder.
4. Using the special tool, remove the valve spring retainer keys.
5. Remove the valve spring retainer.
6. Remove the valve spring.
7. Remove the valve stem seal.
8. To install, reverse the removal procedure.

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Removal

Note. For a valve train noise concern, inspect the valve-to-rocker arm clearance, rocker arms and push rods for wear. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212098-S24834803122005122300000) .
2. Remove the pushrods. For additional information, refer to «PUSH ROD»(ref-212098-S36834600322005122300000) .
3. Remove the tappet guide plate retainer.
4. Remove the valve tappet guide plates.
5. Remove the valve tappets.

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1. Install the valve tappets.
2. Install the valve tappet guide plates.
3. Install the tappet guide plate retainer.
4. Install the pushrods. For additional information, refer to «PUSH ROD»(ref-212098-S36834600322005122300000) .
5. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212098-S24834803122005122300000) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-212098-S15587140292005122300000) .
2. Rotate the crankshaft and align the timing marks.
3. Remove the camshaft sprocket bolt.
4. Remove the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.

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1. Align the timing marks.
2. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
3. Install the camshaft sprocket bolt.
4. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-212098-S15587140292005122300000) .

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1. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) article
2. Remove the cowl vent screen and cowl extension. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) article
3. Disconnect the oxygen sensor (HO2S) (9F472) electrical connector.
4. Remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-212105) article
5. Remove the exhaust manifold heat shield. Remove the bolts. Remove the heat shield.
6. Disconnect the catalytic converter from the exhaust manifold. Remove the bolts.
7. Remove the six bolts and the exhaust manifold. Remove the six bolts.
8. Remove the RH exhaust manifold (9430) and the exhaust manifold gasket (9448). Discard the exhaust manifold gasket.

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1. Position a new exhaust manifold gasket and install the exhaust manifold.
2. Install the bolts. Tighten in the sequence shown, in two stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
3. Connect the catalytic converter. Install the bolts.
4. Install the exhaust manifold heat shield. Install the bolts.
5. Install the exhaust manifold to exhaust gas recirculation (EGR) valve tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-212105) article
6. Connect the HO2S electrical connector.
7. Install the cowl vent screen and cowl extension. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
8. Connect the battery ground cable.

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1. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
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. If equipped, disconnect the secondary air injection tube from the exhaust manifold (9431). Loosen the compression nut.
7. Separate the dual converter Y-pipe from the exhaust manifold. Remove the nuts.
8. Remove the four exhaust manifold bolts and two stud bolts.
9. 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. If equipped, connect the secondary air injection tube to the exhaust manifold.
5. Reposition the power steering pressure line and install the nut.
6. Using the special tool, install a new seal on the power steering pressure line.
7. Connect the power steering pressure line to the power steering pump.
8. Coat the scaling surface of the oil level indicator tube with silicone gasket and sealant.
9. Install the oil level indicator tube.
10. Connect the HO2S electrical connector.
11. Connect the battery.

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212098-S24834803122005122300000) .
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-212097) .
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-212098-S24834803122005122300000) .

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212098-S24834803122005122300000) .
2. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165355) .
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 «EXHAUST MANIFOLD LH»(ref-212098-S31508604922005122300000) .
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-212097) .
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 «EXHAUST MANIFOLD LH»(ref-212098-S31508604922005122300000) .
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 «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165355) .
15. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212098-S24834803122005122300000) .

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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.

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1. Remove the oil level indicator and tube (6754). Remove the nut. Remove the tube.

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1. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
2. Install the oil level indicator tube. Install the tube. Install the nut.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
2. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
3. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
4. Remove the starter motor. For additional information, refer to «STARTERS»(ref-168112) .
5. Remove the bolt and the engine rear plate.
6. Drain the engine oil.
7. Remove the 16 bolts and oil pan.
8. Remove the oil pan gasket from the oil pan.
9. 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. Install the oil pan and the 16 bolts. Tighten the bolts in three stages: Stage 1: Tighten the four corner bolts to 12 Nm (9 lb-ft). Stage 2: Tighten the remaining bolts from back to front to 12 Nm (9 lb-ft). Stage 3: Check all bolts for correct tightness.
4. Install the engine rear plate and the bolt.
5. Install the starter motor. For additional information, refer to «STARTERS»(ref-168112) .
6. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
7. Lower the vehicle.
8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
9. Fill the engine with clean engine oil.
10. Stop the engine.
11. Raise and support the vehicle.
12. Retighten the oil pan bolts from the back to front to 12 Nm (9 lb-ft).
13. Inspect the oil pan gasket for correct alignment.
14. Lower the vehicle.

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-212098-S21382295482005122300000) .
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-212098-S21382295482005122300000) .
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-212097) 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-212110) .
2. Remove the flexplate. Remove the bolts.
3. To install, reverse the removal procedure.

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1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-212098-S28626186572005122300000) .
2. Using a sharp awl, punch one hole into the crankshaft rear seal metal surface between the seal lip and the cylinder block.
3. Screw the threaded end of the special tool into the rear seal. Use the special tool to remove the crankshaft rear seal.

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1. Lubricate the outer lips and the inner seal on the crankshaft rear seal with clean engine oil.
2. Using the special tool, install the crankshaft rear seal. Alternate bolt tightening to correctly seat the crankshaft rear seal.
3. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-212098-S28626186572005122300000) .

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-212098-S21382295482005122300000) .
2. If necessary, remove the oil pump. For additional information, refer to «OIL PUMP»(ref-212098-S17397181382005122300000) .
3. Remove one crankshaft main bearing cap.
4. Remove the crankshaft main bearing.

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1. Install the crankshaft main bearing.
2. Install the crankshaft main bearing cap.
3. Repeat the procedure until all the crankshaft main bearings are inspected and replaced or new bearings are installed.
4. If removed, install the oil pump. For additional information, refer to «OIL PUMP»(ref-212098-S17397181382005122300000) .
5. Install the oil pan. For additional information, refer to «OIL PAN»(ref-212098-S21382295482005122300000) .

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-212098-S21382295482005122300000) .
2. If necessary, remove the oil pump. For additional information, refer to «OIL PUMP»(ref-212098-S17397181382005122300000) .
3. Remove the connecting rod bearing cap.
4. Remove the connecting rod bearings.

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1. Install the connecting rod bearings.
2. Install the connecting rod bearing cap.
3. Repeat the procedure until all the connecting rod bearings are replaced.
4. If removed, install the oil pump. For additional information, refer to «OIL PUMP»(ref-212098-S17397181382005122300000) .
5. Install the oil pan. For additional information, refer to «OIL PAN»(ref-212098-S21382295482005122300000) .

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1. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-212106) .
2. Remove the cowl vent screen and cowl extension. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
3. Remove the engine anti-roll strut. Remove the two bolts.
4. Install the engine lift bracket.
5. Remove the catalytic converters. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
6. Remove the valance panel. Remove three screws. Remove nine pin-type retainers.
7. Remove the RH catalytic converter heat shield. Remove the bolt. Remove the two nuts.
8. Remove the RH engine support insulator-to-subframe nut.
9. Remove the LH engine support insulator-to-subframe nut.
10. Remove the LH front wheel assembly.
11. Remove the nut and two bolts retaining the rear engine support insulator.
12. Partially lower the vehicle.
13. Using the special tool, lift the engine 5.08 cm (2.0 in).
14. Remove the rear engine support insulator.
15. Remove the RH engine support insulator. Remove the through bolt.
16. Remove the LH engine support insulator. Remove the bolts.
17. To install, reverse the removal procedure.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
3. Remove the cowl vent screen and cowl extension. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
4. Recover the refrigerant from the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
5. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-212114) .
6. Drain the engine cooling system. For additional information, refer to «ENGINE - 3.0L (4V)»(ref-212099) .
7. Remove the RH and LH halfshafts. For additional information, refer to «TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(ref-212112) .
8. Remove the nuts and position the steering column input shaft coupling boot aside.
9. Remove the pinch bolt and slide the coupling off the steering gear input shaft.
10. Disconnect the tubes, loosen the clamps and remove the air cleaner outlet pipe.
11. Remove the pin-type retainers and the snow shield.
12. Disconnect the accelerator cable, speed control actuator cable and the throttle return spring from the throttle body.
13. Remove the bolts and position the accelerator cable bracket aside.
14. Disconnect the vacuum hose and the evaporative emissions (EVAP) return tube.
15. Remove the nut and disconnect the manual control lever cable.
16. Disconnect the manual control lever cable from the bracket and position aside.
17. Loosen the bolt and disconnect the 42-pin and transmission range (TR) sensor electrical connectors.
18. Disconnect the upper radiator hose and the heater hose from the thermostat housing.
19. Remove the nut and disconnect the ground strap electrical connector.
20. Disconnect the power steering return hose.
21. Disconnect the generator electrical connectors and position the wire harness aside.
22. Disconnect the A/C suction tube from the accumulator drier. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
23. Disconnect the fuel supply hose. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-212114) .
24. Disconnect the degas bottle hoses.
25. Remove the nut, the bolt and the engine roll restrictor brace.
26. Remove the bolts and the engine roll restrictor.
27. Disconnect the heater hose.
28. Remove the bolt and disconnect the ground electrical connectors.
29. Disconnect the EVAP canister purge valve electrical connector.
30. Loosen the bolt disconnect the powertrain control module (PCM) electrical connector.
31. Remove the nuts and disconnect the three-way catalytic converter from the dual converter Y-pipe.
32. Remove the nuts and the muffler clamp. Separate and remove the three-way catalytic converter from the muffler pipe.
33. Remove the nut and disconnect the A/C discharge tube.
34. Remove the radiator support bracket.
35. Disconnect the lower radiator hose from the radiator and degas bottle supply hose.
36. Disconnect the transmission oil cooler hose.
37. If equipped, disconnect the wire harness electrical connector.
38. Disconnect the auxiliary oil cooler assembly. Disconnect the transmission oil cooler hose, if equipped. Disconnect the power steering return hose.
39. Remove the oil pan drain plug and drain the engine oil. Install the drain plug when finished.
40. Remove the starter motor electrical connector cover.
41. Remove the two nuts and disconnect the starter motor electrical connectors.
42. Remove the two bolts and the starter motor.
43. Remove the bolt and the engine inspection cover.
44. Remove the four torque converter nuts.
45. Remove the nuts and disconnect the LH and RH stabilizer links from the stabilizer bar.
46. Remove the nuts and separate the LH and RH tie-rod ends from the steering knuckles.
47. Position the special tool.
48. Remove the four front subframe-to-body bolts.
49. Using the special tool, lower the powertrain and subframe assembly out of the vehicle.
50. Remove the nut and detach the power steering pressure (PSP) line bracket.
51. Remove the nut and detach the PSP line bracket.
52. Disconnect the PSP line from the power steering pump.
53. Disconnect the spark plug wires.
54. Disconnect the ignition coil electrical connector.
55. Disconnect the output shaft speed (OSS) sensor electrical connector and position the wire harness aside.
56. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
57. Disconnect the transaxle harness electrical connector and position the wire harness aside.
58. Remove the bolt, the nuts and the RH catalytic converter heat shield.
59. Install the special tool to the LH side of the engine.
60. Install the special tool to the RH side of the engine.
61. Using the special tools, support the engine.
62. Remove the two RH engine support insulator-to-transmission bolts.
63. Remove the LH engine support insulator-to-subframe nut.
64. Remove the RH engine support insulator through bolt.
65. Disconnect the catalyst monitor sensor electrical connector.
66. Disconnect the catalyst monitor sensor electrical connector.
67. Remove the bolts and the Y-pipe.
68. Disconnect the lower radiator hose from the coolant pump.
69. Remove the five transmission-to-engine bolts and one stud bolt.
70. Separate the engine from the transmission.

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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. Identify each valve tappet for installation in the original position. 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.

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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-212097) .
3. Remove the valve seal (6A517).
4. Remove the valve (6507/6505). For component tests, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-212097) .
5. To assemble, reverse the disassembly procedure. Lubricate the valve stem and the valve seal with clean engine oil.

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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-212097) .

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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-212097) .

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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-212097) .
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-212097) .
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. Install the bolts. Tighten the bolts in four stages. Stage 1: Tighten the four corner bolts to 12 Nm (9 lb-in). Stage 2: Tighten the remaining bolts to 12 Nm (9 lb-in). Stage 3: Loosen all the bolts one turn. Stage 4: Tighten all the bolts to 12 Nm (9 lb-in).
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. Inspect the upper intake manifold gaskets and install new gaskets as necessary. 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.

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1. Position the engine on the subframe and transmission assembly.
2. Install the transmission-to-engine bolts. Install five bolts. Install one stud bolt.
3. Connect the lower radiator hose to the coolant pump.
4. Install the RH engine support insulator through bolt.
5. Install the dual converter Y-pipe and the bolts.
6. Connect the catalyst monitor sensor electrical connector.
7. Connect the catalyst monitor sensor electrical connector.
8. Install the LH engine support insulator-to-subframe nut.
9. Install the two RH engine support insulator-to-transmission bolts.
10. Using the special tools, secure the engine to the powertrain lift.
11. Install the RH catalytic converter heat shield. Install the two nuts. Position the ground strap and install the bolt.
12. Position the 42-pin connector on the bracket and connect the transaxle harness electrical connector.
13. Connect the turbine shaft speed (TSS) sensor electrical connector.
14. Connect the output shaft speed sensor (OSS) electrical connector.
15. Install the ignition coil and the bolts.
16. Connect the ignition coil electrical connector.
17. Connect the spark plug wires to the ignition coil.
18. Connect the power steering pressure (PSP) tube to the power steering pump.
19. Install the PSP tube bracket and the nut.
20. Install the PSP tube bracket and the nut.
21. Using the special tool, raise the engine, transmission and subframe into the vehicle.
22. Install the four front subframe-to-body bolts.
23. Connect the LH and RH tie-rod ends to the steering knuckles. Install the nuts and cotter pins.
24. Connect the LH and RH stabilizer links to the stabilizer bar.
25. Install the four torque converter nuts.
26. Install the engine rear plate.
27. Install the starter motor.
28. Connect the starter motor electrical connectors.
29. Install the starter motor electrical connector cover.
30. Connect the auxiliary oil cooler assembly. If equipped, connect the transmission oil cooler hose. Connect the power steering return hose.
31. If equipped, connect the wiring harness electrical connector.
32. Connect the transmission oil cooler hose.
33. Connect the lower radiator hose to the radiator and the degas bottle supply hose.
34. Install the radiator support bracket.
35. Connect the A/C discharge tube.
36. Install a new gasket into the Y-pipe flange.
37. Connect the three-way converter to the dual converter Y-pipe and the muffler pipe and install the nuts.
38. Install the exhaust clamp.
39. Connect the powertrain control module (PCM) electrical connector.
40. Connect the evaporative emissions (EVAP) canister purge valve electrical connector.
41. Connect the ground electrical connectors and install the bolt.
42. Connect the heater water hose.
43. Install the engine roll restrictor and the bolts.
44. Install the engine roll restrictor brace and the nut and bolt.
45. Connect the hoses to the degas bottle.
46. Connect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-212114) .
47. Connect the A/C suction tube to the accumulator drier. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
48. Connect the generator electrical connections.
49. Connect the power steering return hose.
50. Connect the ground strap electrical connector.
51. Connect the upper radiator hose and heater hose to the thermostat housing.
52. Connect the transmission range (TR) sensor and the 42-pin electrical connectors.
53. Install the manual control lever cable in the bracket.
54. Connect the manual control lever cable to the manual control lever and install the nut.
55. Connect the vacuum hose and the EVAP return tube.
56. Position the accelerator cable and bracket and install the bolts.
57. Connect the accelerator cable, speed control cable and throttle return spring.
58. Install the snow shield.
59. Position the air cleaner outlet pipe, connect the tubes and tighten the clamps.
60. Connect the steering column to the steering gear input shaft and install the bolt.
61. Position the steering column input shaft coupling boot and install the nuts.
62. Install the RH and LH halfshafts. For additional information, refer to «TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(ref-212112) .
63. Install the cowl extension and cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
64. Install the battery and connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
65. Fill the engine with clean engine oil.
66. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE - 3.0L (4V)»(ref-212099) .
67. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
68. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-212093) .
69. Inspect the engine and cooling system for leaks.