Engine - 3.0L (4V): Removal & Installation Ford Taurus IV facelift

Removal

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-212099-S08526547292005122300000) .
2. Remove the ignition pulse wheel.
3. Install the damper bolt.
4. Remove the LH and RH spark plugs.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
10. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify that the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the LH timing chain and timing chain guide.
14. Remove the damper bolt and the crankshaft sprockets.

Installation

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1. Install the crankshaft sprockets.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and 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 42 and mark the link.
7. 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.
8. Install the LH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
9. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. Position 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.
12. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC)
15. Verify the timing with the following steps. There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and crankshaft timing marks. There should be 30 chain links between the camshaft and crankshaft timing marks.
16. Remove the crankshaft damper bolt.
17. Install the LH and RH spark plugs.
18. Install the ignition pulse wheel.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-212099-S08526547292005122300000) .

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1. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-212099-S08061900062005122300000) and «VALVE COVER RH»(ref-212099-S09563092972005122300000) .
2. Remove the LH and RH spark plugs.
3. Remover the RH front wheel. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
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.

Scheme 778

Removal and Installation

1. Remove the camshaft followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-212099-S40570470552005122300000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. Remove the RH front wheel. For additional information, refer to «WHEELS & TIRES»(ref-212090) .
3. Remove the RH front inner fender splash shield. Remove the screws and the pin-type retainers.
4. Remove the alternator splash shield.
5. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
6. Remove the torque converter inspection cover.
7. Install the flywheel holding tool.
8. Remove the crankshaft pulley.
9. To install, reverse the removal procedure.

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1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-212099-S25163539172005122300000) .
2. Remove the crankshaft damper bolt and washer.
3. Using the special tool, remove the crankshaft damper.

Scheme 788

1. Apply silicone gasket and sealant to the end of the keyway slot.
2. Using the special tool, install the crankshaft damper.
3. Install the bolt and the 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.
4. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-212099-S25163539172005122300000) .

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1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT VIBRATION DAMPER»(ref-212099-S26411310092005122300000) .
2. Using the special tool, remove the crankshaft front oil seal and discard.

Scheme 792

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-212099-S26411310092005122300000) .

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1. Remove the hydraulic lash adjusters. For additional information, refer to «HYDRAULIC LASH ADJUSTER»(ref-212099-S14964620812005122300000) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer, and valve spring.
4. To install, reverse the removal procedure.

Scheme 795

1. Remove the valve spring. For additional information, refer to «VALVE SPRING»(ref-212099-S22564676962005122300000) .
2. Remove the valve seal.

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1. Using the special tool, install the valve seal.
2. Install the valve spring. For additional information, refer to «VALVE SPRING»(ref-212099-S22564676962005122300000) .

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1. Remove the coolant tube bracket bolt.
2. Disconnect and unclip the LH heated oxygen sensor (HO2S) electrical connector from the coolant tube.
3. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
4. Remove the pin-type retainers, bolts and the front splash shield.
5. Remove the coolant tube lower bracket bolt.
6. Remove the nuts and the exhaust manifold. Discard the gasket.
7. To install, reverse the removal procedure.

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1. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(ref-212151) .
2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-212106) .
3. Remove the three retaining screws and the RH cowl top inner panel.
4. Remove the two retaining nuts and position the vacuum outlet manifold assembly aside.
5. Unseat the windshield wiper motor wiring harness grommet. Pull the wiring harness through the grommet.
6. Disconnect the cowl drain tube, remove the three retaining screws and the LH cowl top inner panel.
7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
8. 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 the differential pressure feedback EGR and bracket from the vacuum tubes.
9. Remove the rear support brace. Remove the bolt. Remove the nut. Remove the rear support brace.
10. Remove the steering gear heat shield.
11. Remove the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-212105) .
12. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
13. Remove the nuts in the sequence shown and remove the exhaust manifold. Discard the gasket.

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1. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
2. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
3. Install the EGR tube. For additional information, refer to «ENGINE EMISSION CONTROL»(ref-212105) .
4. Install the steering gear heat shield.
5. Remove the rear support brace. Install the rear support brace. Install the nut. Install the bolt.
6. Install the differential pressure feedback EGR valve sensor and bracket. Connect the differential pressure feedback EGR valve tube and bracket 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.
7. Connect the differential pressure feedback EGR sensor and the RH HO2S electrical connectors.

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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 coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-212100) .
3. Remove the LH exhaust manifold-to-pipe nuts.
4. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-212100) .
5. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212099-S15171099432005122300000) .
6. Remove the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-212099-S10425966492005122300000) .
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 camshaft followers.
10. Remove the hydraulic lash adjusters.
11. Remove the nuts and remove the exhaust manifold. Discard the gasket.
12. Remove the oil level indicator.
13. Remove the nut and the oil level indicator tube. Inspect and, if necessary, install a new O-ring seal.
14. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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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 oil level indicator tube and the nut.
3. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
6. Install the three-bar engine support.
7. Remove the four A/C compressor bracket bolts.
8. Using the special tools, raise the engine away from the A/C compressor bracket.
9. Install the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-212099-S10425966492005122300000) .
10. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212099-S15171099432005122300000) .
11. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-212100) .
12. Install the LH exhaust manifold-to-pipe nuts.
13. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-212100) .

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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 coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-212100) .
3. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212099-S15171099432005122300000) .
4. Remove the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-212099-S42766581852005122300000) .
5. Using the special tools, lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
6. Remove the three-bar engine support.
7. Remove the RH exhaust manifold-to-pipe bolts.
8. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
9. Remove the camshaft followers.
10. Remove the hydraulic lash adjusters.
11. Remove the nuts in the sequence shown and remove the exhaust manifold. Discard the gasket.
12. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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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. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
3. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
4. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
5. Connect the EGR tube to the exhaust manifold.
6. Install the RH exhaust manifold-to-pipe bolts.
7. Install the three-bar engine support.
8. Remove the four A/C compressor bracket bolts.
9. Using the special tools, raise the engine away from the A/C compressor bracket.
10. Install the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-212099-S42766581852005122300000) .
11. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-212099-S15171099432005122300000) .
12. Install the coolant pump bypass tube. For additional information, refer to «ENGINE COOLING»(ref-212100) .

Scheme 850

1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. Position a drain pan and remove the oil filter.
3. Remove the oil pressure sender. Disconnect the electrical connector. Remove the sender.
4. To install, reverse the removal procedure.

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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.

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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 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-212113) .
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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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-212113) .
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.

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-212099-S31507017102005122300000) .
2. Remove the nut, bolts and the oil pump screen and pick-up tube.
3. Remove and discard the O-ring seal.

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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-212099-S31507017102005122300000) .

Scheme 872

1. Remove the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-212099-S25864742852005122300000) .
2. Remove the nuts and the oil pan baffle.

Scheme 873

1. 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.
2. Install the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-212099-S25864742852005122300000) .

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1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-212099-S17609851522005122300000) .
2. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-212113) .
3. Drain the engine oil.
4. Install a new drain plug gasket and tighten the drain plug to 27 Nm (20 lb-ft).
5. Remove the 18 bolts and the oil pan.
6. Remove the nut, bolts and the oil pump screen and pick-up tube.
7. Remove and inspect the O-ring seal.
8. Remove the bolts in the indicated sequence and remove the oil pump.

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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-212113) .
11. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-212099-S17609851522005122300000) .
12. Fill the crankcase to the correct level with clean motor oil.

Scheme 885

1. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F50N»(ref-212110) .
2. Remove the bolts and the flexplate.
3. To install, reverse the removal procedure.

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1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-212099-S30326175492005122300000) .
2. Using the special tools, remove the crankshaft rear oil seal and discard.

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-212099-S30326175492005122300000) .

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1. Raise and support vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. Remove the right front wheel. For additional information, refer to «WHEELS & TIRES»(ref-212090) .
3. Remove the engine support insulator nut.
4. Lower the vehicle.
5. Remove the cowl panel grilles. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
6. Install the 3-Bar Engine Support.
7. Using the special tools, raise the engine to gain clearance necessary to remove the mount.
8. Remove the RH front inner fender splash shield.
9. Remove the two upper bolts and remove the engine support insulator.
10. To install, reverse the removal procedure.

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. Remove the right front wheel. For additional information, refer to «WHEELS & TIRES»(ref-212090) .
3. Remove the engine support insulator nut.
4. Lower the vehicle.
5. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
6. Using the special tools, raise the engine to gain clearance to remove the engine support insulator.
7. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
8. Remove the nut and through bolt and the engine support insulator.
9. To install, reverse the removal procedure.

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1. Remove the bolts and the roll restrictor bracket.
2. Remove the roll restrictor-to-transmission housing bolts. Remove the mount.
3. 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. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-212128) .
3. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-212100) .
4. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
5. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-212114) .
6. Remove the air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-212106) .
7. Remove the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-212142) .
8. Remove the RH and LH halfshafts. For additional information, refer to «AXLE SHAFTS»(ref-154135) .
9. Remove the steering shaft pinch bolt.
10. Remove the ground strap bolt.
11. Remove the bolts and the roll restrictor bracket.
12. Loosen the bolt and disconnect the powertrain control module (PCM) electrical connector.
13. Disconnect the evaporative emission (EVAP) system hoses.
14. Remove the pin-type retainers and the accelerator cable splash shield.
15. Disconnect the accelerator cable and the cruise control cable. Detach the cables from the bracket.
16. Disconnect the transaxle range (TR) sensor electrical connector.
17. Remove the nut and unclip the shifter cable from the bracket.
18. Loosen the bolt and disconnect the harness connector.
19. Disconnect the low pressure A/C tube spring lock coupling at the accumulator/drier. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
20. Remove the heater hose bracket nut.
21. Disconnect the heater hoses.
22. Remove the heater hose bracket nut.
23. Disconnect the coolant recovery bottle hose.
24. Remove the nut and disconnect the starter motor ground cable.
25. Disconnect the upper radiator hose.
26. Disconnect the power steering fluid hose from the reservoir.
27. Remove the two LH exhaust manifold-to-pipe nuts.
28. Drain the engine oil.
29. Remove the pin-type retainers, bolts and the front splash shield.
30. Remove the LH and RH inner fender splash shield pin-type retainers and remove the splash shield.
31. Remove the starter cable cover.
32. Remove the nut and disconnect the cable from the starter.
33. Remove the LH and RH stabilizer bar end link nuts.
34. Remove the LH and RH tie-rod end cotter pin and nut.
35. Using the special tool, separate the tie-rod end from the knuckle.
36. Remove the RH exhaust manifold-to-pipe bolts.
37. Remove the nuts and the dual converter Y-pipe.
38. Disconnect the power steering and transaxle hoses from the cooler.
39. Disconnect the transaxle cooler hose.
40. Remove the nut and disconnect the A/C high pressure line at the condenser.
41. Remove four bolts and remove the radiator support bracket.
42. Disconnect the lower radiator hose and the reservoir supply hose.
43. If equipped, disconnect the engine block heater electrical connector.
44. If equipped, unclip the engine block heater harness.
45. Remove the torque converter inspection cover.
46. Remove the four torque converter-to-flexplate nuts.
47. Using the special tool, support the subframe.
48. Remove the four subframe bolts and lower the subframe engine/transaxle assembly.
49. Remove the coolant tube lower mounting bolt.
50. Remove the coolant tube mounting bolt and position the tube away from the cylinder head.
51. Remove the engine support brace.
52. Install the special tools.
53. Using the special tools and a suitable engine hoist, support the engine and transaxle at the LH and RH cylinder heads.
54. Disconnect the power steering pressure tube and remove the clamp bolt.
55. Remove the LH engine mount-to-frame nut.
56. Remove the RH engine mount-to-frame nut.
57. Remove the engine bracket-to-transaxle bolts.
58. Remove the bolts and separate the engine from transaxle.

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Scheme 1022

1. Rotate the tensioner and remove the accessory drive belt.
2. Install the special tool to hold the flywheel.
3. Remove the crankshaft pulley.
4. Remove the crankshaft damper bolt and washer.
5. Using the special tool, remove the crankshaft vibration damper.
6. Remove the bolts and the flexplate.
7. Mount the engine on a suitable engine stand.
8. Remove the generator. Disconnect the electrical connector. Remove the bolt. Remove the studs. Remove the generator.
9. Remove the bolts and the power steering pump.
10. Disconnect the A/C compressor. Disconnect the compressor electrical connector. Disconnect the pressure sensor electrical connector. Disconnect the harness from the bracket.
11. Remove the bolts and the A/C compressor.
12. Remove the bolts and the A/C compressor bracket.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Disconnect the harness retainers from the front LH valve cover studs.
15. Disconnect the oil pressure sensor electrical connector.
16. Remove the crankshaft position (CKP) sensor. Disconnect the electrical connector. Remove the bolt and the CKP sensor.
17. Loosen and disconnect the exhaust gas recirculation (EGR) tube from the manifold.
18. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors. Detach the harness from the throttle body stud bolt.
19. Disconnect the hose from the positive crankcase ventilation (PCV) valve.
20. Disconnect the EGR vacuum regulator solenoid electrical connector.
21. Remove the bolts and the upper intake manifold. Inspect the gaskets. Discard if damaged.
22. Disconnect the differential pressure feedback EGR sensor and the RH heated oxygen sensor (HO2S) electrical connectors.
23. Disconnect the coil-on-plug electrical connectors and detach the wiring harness retainers.
24. Remove the differential pressure feedback EGR sensor and bracket. Detach the electrical connector pin-type retainer. Remove the bolts from the differential pressure feedback EGR sensor and bracket. Remove the differential pressure feedback EGR sensor and bracket from the vacuum tubes.
25. Disconnect the knock sensor (KS) electrical connector.
26. Remove the bolt and KS.
27. Disconnect and unclip the LH HO2S electrical connector from the coolant tube.
28. Remove the bolts and the RH and LH ignition coils.
29. Disconnect the fuel injector electrical connectors.
30. Disconnect the fuel injection pressure and temperature sensor vacuum tube and the electrical connector.
31. Remove the bolts and the lower intake manifold. Remove and discard the gaskets.
32. Disconnect the engine coolant temperature (ECT) sensor electrical connector and detach the pin-type retainer.
33. Disconnect the two hose clamps and remove the coolant tube assembly.
34. Detach the wiring harness retainer from the stud.
35. Remove the nut and position the radio interference capacitor aside.
36. Remove the fuel charging harness. Remove the harness nut. Disconnect the harness from the stud.
37. Remove the nuts and the LH exhaust manifold. Discard the gasket.
38. Remove the nuts and the RH exhaust manifold. Discard the gasket.
39. Remove the coolant pump drive belt cover.
40. Rotate the drive belt tensioner clockwise and remove the coolant pump belt.
41. Cut and remove the coolant pump belt. Discard the belt.
42. Disconnect the coolant pump outlet hose.
43. Disconnect the heater hose from the coolant pump and remove the heater hose assembly.
44. Remove the bolts and the coolant pump.
45. Remove the studs and the RH and LH valve cover. Remove and discard the gaskets.
46. Remove the bolt and stud and the coolant tube.
47. Remove the bolts and studs and the oil pan. Discard the gasket.
48. Remove the bolts, nut and the oil pick-up tube and screen.
49. Remove the nuts and the oil pan baffle.
50. Remove and discard the oil filter.
51. Remove the stud and the oil level indicator and tube.
52. Remove the oil pressure sensor.
53. Remove the bolts, studs and the front cover. Remove and discard the front cover gaskets.
54. Remove the crankshaft front seal from the front cover and discard.
55. Remove the ignition pulse wheel.
56. Install the damper bolt.
57. Remove the LH and RH spark plugs.
58. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
59. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the NEUTRAL position.
60. Verify that the RH camshafts are in the neutral position.
61. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
62. Remove the bolts, RH timing chain guide and the timing chain.
63. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase key way in the 11 o'clock position. This will position the LH camshafts in the NEUTRAL position.
64. Verify the LH camshafts are in the neutral position.
65. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
66. Remove the LH timing chain and timing chain guide.
67. Remove the damper bolt and the crankshaft sprockets.
68. Using the special tools, remove the coolant pump drive pulley and discard.
69. Using the special tools, remove the camshaft oil seal and discard.
70. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
71. Loosen the LH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
72. Loosen the RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
73. Remove the LH and RH camshafts.
74. Remove the LH and RH camshaft followers. Mark the location of the followers using a permanent-type marker.
75. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the gaskets.
76. Remove the bolts and the crankcase cover. Discard the gasket.
77. Remove the bolts in the indicated sequence and remove the oil pump.
78. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
79. Using the special tool, remove the piston/rod assembly from the engine block.
80. Remove the engine block from the stand and place on a workbench.
81. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
82. Remove the crankshaft rear main seal and remove the crankshaft.
83. Remove the crankshaft key.
84. Remove the crankshaft thrust bearing from the cylinder block.
85. Remove the bearings from the lower cylinder block.
86. Remove the crankshaft main bearings from the cylinder block.
87. Inspect the cylinder block, lower cylinder block, cylinder heads, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-212097) .

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