Engine - 3.9L: Other Ford Thunderbird XI

Engine Code Information

The engine code information label is located on the valve cover. The label contains, among other information

1. the engine calibration number
2. the engine build date
3. the engine plant code
4. the engine code

Exhaust Emission Control System

Refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV .

Induction System

The air/fuel mixture needed for burning in the cylinders is provided by the Multiport Fuel Injection (MFI) system. Refer to FUEL SYSTEM for additional information.

Fuel is

1. supplied from the fuel tank by the fuel pump.
2. regulated by the fuel pressure sensor.
3. delivered to the injector supply manifold.

A dual damper has been added to reduce pressure fluctuations caused by the fuel injectors.

Crankshaft

The crankshaft is supported on the bottom of the cylinder block by five steel-backed, over-plated, aluminum crankshaft main bearings.

To provide smooth engine operation, the piston crankpins are positioned to provide a power impulse every 90 degrees of crankshaft rotation. The spacing provides smooth and quiet operation.

Camshafts

The camshafts

1. are arranged in pairs, one each (intake and exhaust) on each cylinder head.
2. are synchronized through a secondary timing chain.
3. depress the direct acting mechanical tappets to actuate the valves.

Valve Train

The valves are actuated by a direct acting mechanical bucket and shim. The direct acting mechanical tappets and shims

1. provide lash adjustment through a shim selected by thickness.
2. ride on the camshaft lobes.

Positive Crankcase Ventilation System

The engine is equipped with a positive, closed-type crankcase ventilation system which recycles the crankcase vapors to the throttle body.

Oil Pump

The rotary spur oil pump develops the oil pressure.

1. The oil pump is bolted to the front of the cylinder block.
2. The oil pump is rotated by the crankshaft.
3. A full flow oil filter is externally mounted on the upper sump.

If the filter element becomes blocked, a spring-loaded bypass valve opens to allow uninterrupted flow of oil to the engine.

Engine Cooling System

The engine is liquid-cooled

1. by a centrifugal water pump driven by the drive belt.
2. a water thermostat is used to restrict coolant flow until the engine reaches normal operating temperature.

Drive Belt System

Accessories mounted on the front of the engine are belt-driven by the crankshaft and an automatically tensioned serpentine drive belt is routed over the following components

1. water pump
2. A/C compressor
3. generator (GEN)
4. drive belt tensioner
5. drive belt idler pulley
6. crankshaft pulley
7. power steering pump
8. hydraulic cooling fan pump

Refer to ENGINE SYSTEM-GENERAL INFORMATION .

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1. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) or «TIMING DRIVE COMPONENTS - SECONDARY»(ref-204559-S00879160002005111300000) .
2. Use a feeler gauge to measure each valve clearance and record its location.
3. Remove the camshafts. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .
4. Remove the shims.
5. Select shims and mark the installation location.
6. Replace the shims.
7. Install the camshaft. For additional information, refer to «CAMSHAFT»(ref-204559-S13019775132005111300000) .
8. Measure the new valve clearances.
9. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - PRIMARY»(ref-204559-S09416534882005111300000) or «TIMING DRIVE COMPONENTS - SECONDARY»(ref-204559-S00879160002005111300000) .

VALVE CLEARANCE CHECK

1. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-204559-S32423370792005111300000) or «VALVE COVER RH»(ref-204559-S16983498872005111300000) .
2. Remove the spark plugs.
3. Measure and record all valve clearances.
4. If the valve clearances are out of specification, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-204559-S03844227602005111300000) .
5. To assemble, reverse the inspection procedure.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
2. Remove the air cleaner outlet tube.
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .
4. Remove the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .
5. Remove the engine compartment brace.
6. Disconnect the accelerator and speed control cables.
7. Disconnect the vacuum hoses.
8. Disconnect the vacuum hose.
9. Disconnect the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube.
10. Disconnect the Camshaft Position (CMP) sensor electrical connector and separate the connector from the fuel injection supply manifold.
11. Disconnect the evaporative emission canister purge valve hose.
12. Disconnect the fuel pressure sensor electrical connector.
13. Disconnect the vacuum connector from the fuel pressure sensor.
14. Disconnect the fuel line. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
15. Remove the electrical connectors from the bracket. LH Knock Sensor (KS). Cylinder Head Temperature (CHT) sensor.
16. Remove the nut and the bracket.
17. Remove the bracket. Remove the hose. Remove the nuts and the bracket.
18. Raise the engine wiring harness and disconnect the LH fuel injector connectors.
19. Disconnect the electrical connectors. Idle Air Control (IAC) valve. Throttle Position (TP) sensor.
20. Disconnect the crankcase ventilation tube from the RH valve cover.
21. Disconnect the hoses. Squeeze the clamps and disconnect the hoses from the throttle body. Detach the hose from the clip.
22. Raise the engine wiring harness and disconnect the RH fuel injectors.
23. Remove the differential pressure feedback sensor. Disconnect the electrical connector. Disconnect the hoses. Remove the bolts and the sensor.
24. Remove the bolts and the stud (2) in the sequence shown.
25. Remove the intake manifold.
26. Clean the sealing surfaces. Inspect the gaskets and install new gaskets if necessary.

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1. If removed, install the gaskets.
2. Install the intake manifold and tighten the bolts in the sequence shown.
3. Install the differential pressure feedback sensor. Install the sensor and the bolts. Connect the electrical connector. Connect the hoses.
4. Connect the RH fuel injector electrical connectors, and position the engine wiring harness.
5. Connect the hoses. Connect the hoses to the throttle body and position the clamps. Attach the hose to the clip.
6. Connect the crankcase ventilation tube.
7. Connect the IAC valve and TPS electrical connectors.
8. Connect the LH fuel injector electrical connectors and position the engine wiring harness.
9. Install the bracket. Install the bracket and nuts. Install the hose.
10. Install the bracket and the nut.
11. Install the electrical connectors on the bracket. Install the LH KS electrical connector. Install the CHT sensor electrical connector.
12. Connect the fuel hose. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
13. Connect the vacuum connector to the fuel pressure sensor.
14. Connect the fuel pressure sensor electrical connector.
15. Connect the evaporative emission canister purge valve hose.
16. Connect the CMP sensor electrical connector, and position the connector on the fuel injection supply manifold.
17. Connect the exhaust manifold to EGR valve tube.
18. Connect the vacuum hose.
19. Connect the vacuum hoses.
20. Connect the accelerator and speed control cables.
21. Install the engine compartment brace.
22. Install the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .
23. Install the air cleaner outlet tube.
24. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
25. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .

Material

MATERIAL CHART

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
2. Remove the air cleaner outlet tube.
3. Remove the air cleaner housing. Disconnect the Mass Air Flow (MAF) sensor electrical connector. Remove the bolt. Remove the housing.
4. Disconnect the crankcase ventilation tube.
5. Disconnect the fuel hose. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
6. Disconnect the evaporative emission canister purge valve hose.
7. Remove the Vapor Management Valve (VMV) cover.
8. Remove the VMV. Disconnect the vacuum hose. Disconnect the purge hose. Disconnect the electrical connector and the push pin. Remove the nuts and the valve.
9. Remove the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. Disconnect the electrical connector. Remove the screws and the EGR vacuum regulator solenoid.
10. Remove the bracket. Remove the hose. Remove the bracket.
11. Position the engine wiring harness up.
12. Remove the ignition coil cover. Inspect the gasket and install a new gasket as necessary.
13. Disconnect the ignition coil electrical connectors.
14. Remove the four LH ignition coils.
15. Disconnect the three wiring harness retainers.
16. Remove the fuel hose bracket bolt from the LH shock tower.
17. Loosen the bolts and position the power steering pump reservoir aside.
18. Remove the nut and the oil level indicator tube.
19. Remove the LH valve cover. Loosen the bolts in the sequence shown.
20. Clean the sealing surfaces.
21. Inspect and install new gaskets if necessary.

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1. Apply two beads of silicone gasket and sealant as shown.
2. Install the LH valve cover. Position the valve cover and tighten the bolts in the sequence shown.
3. Install the oil level indicator tube. Inspect the O-ring seal and install a new O-ring seal if necessary.
4. Install the power steering pump reservoir.
5. Install the fuel hose bracket bolt.
6. Connect the three wiring harness retainers.
7. Install the four LH ignition coils.
8. Connect the ignition coil electrical connectors.
9. Install the ignition coil cover.
10. Install the engine wiring harness.
11. Install the bracket. Install the bracket. Install the hose.
12. Install the EGR vacuum regulator solenoid. Install the EGR vacuum regulator solenoid and screws. Connect the electrical connector.
13. Install the VMV. Install the nuts. Connect the purge hose. Connect the vacuum hose. Connect the electrical connector and wiring harness push pin.
14. Install the VMV cover.
15. Connect the hose.
16. Connect the crankcase ventilation tube.
17. Connect the fuel hose. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
18. Install the air cleaner housing. Install the housing. Install the bolt. Connect the MAF sensor electrical connector.
19. Install the air cleaner outlet tube.
20. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .

MATERIAL CHART

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
2. Remove the air cleaner outlet tube.
3. Remove the bolts and position the hydraulic cooling fan reservoir aside.
4. Disconnect the crankcase ventilation hose.
5. Remove the bolts and position the wiring harness bracket aside.
6. Remove the ignition coil cover. Inspect the gasket and install a new gasket as necessary.
7. Disconnect the ignition coil electrical connectors.
8. Raise the engine wiring harness and disconnect the four fuel injector electrical connectors.
9. Disconnect the three wiring harness retainers.
10. Remove the four RH ignition coils.
11. Remove the nut and position the wiring harness aside.
12. Remove the RH valve cover. Loosen the bolts in the sequence shown.
13. Clean the sealing surfaces.
14. Inspect and install new gaskets as necessary.

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1. Apply two beads of silicone gasket and sealant as shown.
2. Install the RH valve cover. Tighten the bolts in the sequence shown.
3. Install the ignition coils.
4. Position the wiring harness and install the nut.
5. Install the three wiring harness retainers.
6. Connect the four fuel injector electrical connectors and position the engine wiring harness.
7. Connect the ignition coil electrical connectors.
8. Inspect the gasket and install a new gasket as necessary. Install the ignition coil cover.
9. Install the wiring harness bracket.
10. Connect the crankcase ventilation hose.
11. Install the hydraulic cooling fan reservoir.
12. Install the air cleaner outlet tube.
13. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .

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MATERIAL SPECIFICATION

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1. Remove the hydraulic cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-204560) .
2. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139103) .
3. Remove and discard the bolt.
4. Using the special tool, remove the crankshaft pulley.

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1. Apply a bead of silicone gasket and sealant to the keyway.
2. Using the special tool, install the crankshaft pulley.
3. Install a new bolt and tighten in four stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Loosen the bolt two complete turns. Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139103) .
5. Install the hydraulic cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-204560) .

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1. Remove the front crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204559-S32594603122005111300000) .
2. Using the special tool, remove the front crankshaft seal. Discard the seal.

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1. Using the special tool, install a new front crankshaft seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204559-S32594603122005111300000) .

MATERIAL SPECIFICATION

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1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .
2. Drain the engine oil.
3. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-204559-S32423370792005111300000) .
4. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-204559-S16983498872005111300000) .
5. Remove the engine cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-204560) .
6. Loosen the water pump pulley bolts.
7. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-163638) .
8. Remove the water pump pulley. Discard the bolts.
9. Remove the bracket. Remove the nuts. Remove the bracket.
10. Remove the lower radiator hose stud bolts.
11. Disconnect the lower radiator hose from the thermostat housing.
12. Disconnect the heater hose.
13. Remove the idler pulleys.
14. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204559-S32594603122005111300000) .
15. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
16. Disconnect the power steering reservoir hose and drain the reservoir
17. Disconnect the Power Steering Pressure (PSP) switch.
18. Remove the bolts and position the power steering pump aside.
19. Remove the power steering pump bracket.
20. Disconnect the hydraulic cooling fan pump reservoir hose and drain the reservoir.
21. Disconnect the electrical connector.
22. Remove the hydraulic fan pump high pressure hose bracket. Remove the bolt. Remove the bracket.
23. Remove the hydraulic cooling fan pump.
24. Remove the hydraulic cooling fan pump bracket.
25. Lower the vehicle.
26. Disconnect the five wiring harness clips.
27. Remove the engine front cover. Remove the bolts in the sequence shown. Remove the engine front cover.
28. Clean the sealing surfaces.

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1. Install new gaskets.
2. Apply silicone gasket and sealant in eight places.
3. Install the engine front cover. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
4. Connect the five wiring harness clips.
5. Raise the vehicle.
6. Install the hydraulic cooling fan pump bracket.
7. Install the hydraulic cooling fan pump.
8. Install the hydraulic fan pump high pressure hose bracket. Install the bracket. Install the bolt.
9. Connect the electrical connector.
10. Connect the hydraulic cooling fan reservoir hose.
11. Install the power steering pump bracket.
12. Install the power steering pump.
13. Connect the Power Steering Pressure (PSP) switch.
14. Connect the power steering reservoir hose.
15. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
16. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204559-S32594603122005111300000) .
17. Install the idler pulleys.
18. Connect the heater hose.
19. Connect the lower radiator hose to the thermostat housing.
20. Install the stud bolts.
21. Install the bracket. Install the bracket. Install the nuts.
22. Position the water pump pulley and loosely install new bolts.
23. Install the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-163638) .
24. Tighten the bolts in two stages. Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten an additional 45 degrees.
25. Install the engine cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-204560) .
26. Install the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-204559-S16983498872005111300000) .
27. Install the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-204559-S32423370792005111300000) .
28. Fill the engine with clean engine oil.
29. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .
30. Fill and bleed the hydraulic cooling fan. For additional information, refer to «ENGINE COOLING»(ref-204560) .
31. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-204554) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204559-S38123580392005111300000) .
2. Raise the vehicle.
3. Remove the Crankshaft Position (CKP) sensor and the torque converter cover.
4. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
5. Lower the vehicle.
6. Make sure the lobes of the camshaft are facing upwards. If not, repeat step 4 .
7. Install the special tool on the RH cylinder head.
8. Loosen the exhaust camshaft sprocket bolt.
9. Loosen the intake camshaft sprocket bolt and slide the camshaft sprockets forward on the bolt.
10. Remove the RH timing chain tensioner.
11. Remove the tensioner arm.
12. Remove the timing chain guide.
13. Remove the RH primary timing chain.
14. Remove the special tool from the RH head.
15. Install the special tool on the LH head.
16. Loosen the exhaust camshaft sprocket bolt.
17. Loosen the intake sprocket bolt and slide the camshaft sprockets forward on the bolts.
18. Remove the LH timing chain tensioner.
19. Remove the tensioner arm.
20. Remove the timing chain guide.
21. Remove the LH primary timing chain and crankshaft sprocket as an assembly.

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1. Reset the timing chain tensioners. Hold the lever toward the tensioner piston. Using finger pressure, compress the tensioner. Push the lever down and install a drill rod to lock the piston.
2. Position the LH timing chain and crankshaft gear. Position the timing chain over the LH intake camshaft sprocket. Position the crankshaft gear in the timing chain. Position the timing chain and crankshaft gear over the crankshaft as an assembly.
3. Install the LH timing chain guide.
4. Install the LH timing chain tensioner arm.
5. Install the LH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
6. Install a tie strap to take up the slack in the timing chain.
7. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the LH exhaust camshaft sprocket and tighten the camshaft bolts in two stages. Stage 1 : Tighten to 20 N.m (15 lb-ft). Stage 2 : Tighten an additional 90 degrees.
8. Remove the special tool.
9. Remove the tie strap.
10. Install the special tool on the right cylinder head.
11. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
12. Install the RH timing chain guide.
13. Install the RH timing chain tensioner arm.
14. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
15. Install a tie strap to take up the slack in the timing chain.
16. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the RH exhaust camshaft sprocket and tighten the camshaft sprocket bolts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
17. Remove the special tool. Remove the tie strap.
18. Raise the vehicle.
19. Remove the special tool.
20. Install the CKP sensor and the torque converter cover.
21. Lower the vehicle.
22. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204559-S38123580392005111300000) .

MATERIAL S

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1. Remove the secondary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - SECONDARY»(ref-204559-S00879160002005111300000) .
2. Remove the special tool.
3. Remove the RH camshaft bearing caps. Remove the bolts. Remove the RH camshaft bearing caps.
4. Remove the RH camshafts (6A270 intake and 6A272 exhaust).
5. Remove the LH camshaft bearing caps. Remove the bolts. Remove the LH camshaft bearing caps.
6. Remove the LH camshafts.

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1. Position the LH camshafts on the camshaft journals.
2. Install the LH camshaft bearing caps. Position the bearing caps. Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
3. Install the RH camshafts.
4. Install the RH camshaft bearing caps. Position the bearing caps. Install the bolts. Tighten the bolts in three stages in the sequence shown. Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
5. Using feeler gauges, confirm that the tappet and shim clearances are within specification.
6. Install the special tool on the LH head.
7. Install the secondary timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - SECONDARY»(ref-204559-S00879160002005111300000) .

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1. Hold the steering wheel in the straight-ahead position using a suitable holding device.
2. Remove the bolts and position the power steering reservoir aside.
3. Remove the nut and position the oil level indicator tube aside.
4. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
5. Remove the screws and remove the sight shield.
6. Remove the Three-Way Catalytic (TWC) converter. .
7. Loosen the bolt.
8. Remove the pinch bolt and disconnect the intermediate shaft.
9. Remove the exhaust manifold. Remove the eight bolts and discard. Remove the exhaust manifold and discard the gasket.
10. Inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .

MATERIAL CHART

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
2. Drain the engine oil.
3. Remove the lower splash shield.
4. Remove and discard the oil filter.
5. Disconnect the oil pressure sender.
6. Remove the oil filter adapter assembly. Discard the seal.
7. Clean the sealing surfaces.

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1. Install a new seal and the oil filter adapter. Tighten the bolts in two stages. Stage 1: Tighten to 13 N.m (10 lb-ft). Stage 2: Tighten an additional 90 degrees.
2. Connect the oil pressure sender.
3. Install the oil filter. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.
4. Install the lower splash shield.
5. Lower the vehicle.
6. Fill the engine with clean engine oil.

MATERIAL SPECIFICATION

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1. Remove the bolts and position the power steering reservoir aside.
2. Remove the oil level indicator.
3. Remove the nut and the oil level indicator and tube.

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1. Inspect the O-ring seal and install a new O-ring seal as necessary. Install the oil level indicator tube.
2. Install the nut.
3. Install the oil level indicator.
4. Position the power steering reservoir and install the bolts.

MATERIAL SPECIFICATION

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
2. Remove the front valance panel. Remove the bolts. Remove the pin-type retainer.
3. Remove the bolts and the front crossbrace.
4. Remove the oil pan drain plug and drain the engine oil.
5. Remove the oil pan. Inspect the gasket and install a new one if necessary.

MATERIAL SPECIFICATION

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1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-204559-S18149461952005111300000) .
2. Using the special tools, remove the crankshaft rear oil seal. Discard the seal.

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1. Position the rear oil seal with the protective installer onto the end of the crankshaft.
2. Using the special tool, install a new crankshaft rear oil seal.
3. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-204559-S18149461952005111300000) .

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MATERIAL SPECIFICATION

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1. Using the special tool, remove the valve spring retainer keys.
2. Remove the valve spring assemblies. Remove the valve spring retainers. Remove the valve springs. For component tests for the valve spring, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .
3. Remove the valve stem seal.
4. Remove the valve. For component tests for the valve, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) . For component tests for the cylinder head, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204558) .
5. Repeat the procedure until all of the valves are removed from the cylinder head.
6. Remove the spark plugs. For additional information, refer to «SPARK PLUG»(ref-142371-S00693754512002101400000) .
7. Remove the Cylinder Head Temperature (CHT) sensor sensor.
8. Remove the Camshaft Position (CMP) sensor.

MATERIAL SPECIFICATION

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1. Position the rear oil seal with the protective installer onto the end of the crankshaft.
2. Using the special tools, install the rear main seal.
3. Apply three continuous beads of sealer of silicone gasket and sealant.
4. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in two stages. Tighten the bolts to 15 N.m (11 lb-ft). Tighten the bolts to 25 N.m (18 lb-ft).
5. Install the flexplate and tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 15 N.m (11 lb-ft). Stage 2: Tighten to 110 N.m (81 lb-ft).
6. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
7. Install a new gasket, the oil pump and the bolts.
8. Verify the retaining washers are in place.
9. Install the oil pump screen cover and tube.
10. Install the oil pan.
11. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 12 N.m (9 lb-ft).
12. Install the throttle body heater return hose.
13. Install the knock sensors.
14. Position the cylinder heads. Install new gaskets.
15. Install and tighten the RH head bolts in four stages in the sequence shown. Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
16. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.
17. Install and tighten the LH head bolts in four stages in the sequence shown. Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
18. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.
19. If removed, install the tappets and shims. If new tappets and shims are to be installed or if they cannot be identified, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-204559-S03844227602005111300000) .
20. Position the LH camshafts on the camshaft journals.
21. Install the LH camshaft bearing caps. Position the bearing caps. Install the bolts. Tighten the bolts in three stages in the sequence shown. Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
22. Position the RH camshafts on the camshaft journals.
23. Install the RH camshaft bearing caps. Position the bearing caps. Install the bolts. Tighten the bolts in three stages in the sequence shown. Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
24. Using a feeler gauge, confirm that the bucket tappet and shim clearances are within specification.
25. Install the special tool on the LH head.
26. Collapse the tensioners. Insert a thin wire into the check valve and apply hand pressure until the tensioner is fully collapsed. Install a wire in the side to retain the tensioner.
27. Position the tensioner.
28. Install the secondary timing chain tensioner bolts.
29. Position the intake sprocket, chain and exhaust sprocket on the camshaft as an assembly.
30. Loosely install the intake and exhaust sprocket bolts.
31. Reset the timing chain tensioner. Hold the lever toward the tensioner piston. Using finger pressure, compress the tensioner. Push the lever down and install a drill rod to lock the piston.
32. Position the LH timing chain and crankshaft gear. Position the timing chain over the LH intake camshaft sprocket. Position the crankshaft gear in the timing chain. Position the timing chain and crankshaft gear over the crankshaft as an assembly.
33. Install the LH timing chain guide.
34. Install the LH timing chain tensioner arm.
35. Install the LH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
36. Install a tie strap to take up the slack in the timing chain.
37. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the LH exhaust camshaft sprocket and tighten the camshaft sprocket bolts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
38. Remove the special tool.
39. Install the special tool on the right cylinder head.
40. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
41. Install the RH timing chain guide.
42. Install the RH timing chain tensioner arm.
43. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
44. Install a tie strap to take up the slack in the timing chain.
45. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the RH camshaft sprockets and tighten the bolts in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
46. Remove the special tool and the two tie straps.
47. Apply silicone gasket and sealant in eight places.
48. Install the engine front cover. Install new gaskets. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
49. Using the special tool, install the front crankshaft seal.
50. Apply silicone gasket and sealant to the crankshaft pulley keyway.
51. Using the special tool, install the crankshaft pulley.
52. Install the washer and a new bolt and tighten in two stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Tighten an additional 80 degrees. Remove the flexplate holding tool.
53. Install a new seal and the oil filter adapter.
54. Install the oil filter. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.
55. Install the new exhaust manifold gaskets, the exhaust manifolds and the new bolts.
56. Install the starter motor.
57. Install the water pump. Inspect the O-ring seal and install a new O-ring seal as necessary. Position a new water pump gasket. Position the water pump. Install the bolts and tighten in two stages. Stage 1: Tighten to 8 N.m (71 lb-in). Stage 2: Tighten an additional 90 degrees.
58. Inspect and install new gaskets as necessary.
59. Apply four beads of silicone gasket and sealant as shown.
60. Install the valve covers. Tighten the bolts in the sequence shown.
61. Install the oil level indicator and tube. Install the nut.
62. Install the eight ignition coils.
63. Install the four bolts and the thermostat housing.
64. Install the intake manifold and tighten the bolts and stud bolt (2) in the sequence shown. Inspect and install a new gasket if necessary.
65. Position the wiring harness and install the nuts.
66. Install the bracket.
67. Install the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube. Finger-tighten both fittings. Tighten the upper fitting.
68. Tighten the lower fitting.
69. Connect the fuel injector connectors and position the engine wiring harness.
70. Install the bracket and the two nuts.
71. Install the water outlet pipe. Inspect and install a new gasket if necessary. Install the four bolts. Connect the hoses.
72. Connect the knock sensor connector and install onto the bracket.
73. Install the CHT sensor and KS electrical connectors on the bracket.
74. Connect the fuel pressure sensor electrical connector.
75. Connect the HO2S connectors to the brackets.
76. Remove the special tool, install the CKP sensor.
77. Connect the CKP sensor connector.
78. Connect the two pin-type retainers.
79. Install the wiring harness to the front cover on the LH side.
80. Install the wiring harness to the front cover on the RH side.
81. Install the power steering pump bracket.
82. Install the power steering pump.
83. Connect the Power Steering Pressure (PSP) switch.
84. Install the hydraulic cooling fan pump bracket.
85. Install the hydraulic cooling fan pump.
86. Connect the electrical connector.
87. Install the A/C compressor.
88. Connect the electrical connector and the retaining clip.
89. Position the generator and loosely install the bolts and nut. Tighten the upper bolt and nut.
90. Tighten the lower expanding bushing and bolt in two stages. Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
91. Tighten the bolt.
92. Connect the electrical connector.
93. Install the two idler pulleys.
94. Position the water pump pulley and loosely install new bolts.
95. Install the drive belt tensioner. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139103) .
96. Tighten the water pump pulley bolts in two stages. Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten an additional 45 degrees.
97. Install the inlet tube support bracket.
98. Install the six wiring harness retainers.
99. Connect the fuel injector connectors and position the engine wiring harness.
100. Connect the eight ignition coil connectors.
101. Install the ignition coil covers.
102. Install the throttle body.
103. Connect the hoses (1) and install the hose in the clip (2).
104. Connect the Positive Crankcase Ventilation (PCV) line.
105. Connect the Idle Air Control (IAC) and Throttle Position Sensor (TPS) electrical connectors.
106. Connect the air assist valve hose.
107. Connect the EGR and vacuum regulator solenoid electrical connections.
108. Connect the CMP sensor connector and connect the connector locator.
109. Connect the exhaust manifold to EGR valve tube.
110. Connect the vacuum hose.
111. Connect the vacuum harness.

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MATERIAL CHART

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1. Install the special tool.
2. Install the special tool.
3. Using a floor crane and a spreader bar (303-D089) to support the engine, remove the engine from the engine stand.
4. Install the engine to the transmission and install the bolts.
5. Install the transmission wiring harness.
6. Using a floor crane and the special tool, install the engine onto the subframe.
7. Install the LH and the RH upper engine mounts.
8. Remove the engine lifting equipment.
9. Remove the special tool.
10. Remove the special tool.
11. Install a new nylon O-ring seal on the hydraulic fan high pressure line.
12. Install the hydraulic fan pump high pressure line and install the hydraulic fan high pressure line bracket bolt.
13. Install a new nylon O-ring seal on the high pressure power steering line.
14. Install the power steering high pressure line and power steering high pressure line bracket bolt.
15. Connect the transmission cooler lines.
16. Install the transmission cooler line bracket.
17. Connect heater hose.
18. Connect the KS electrical connector.
19. Connect the radiator hoses.
20. Install the lower radiator hose.
21. Install the bracket.
22. Connect the A/C manifold and tube.
23. Connect the block heater, if equipped.
24. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
25. Install the four front and the four center crossmember bolts.
26. Install the transmission crossmember bolts.
27. Install the engine crossmember.
28. Remove the safety stands from the rear of the vehicle.
29. Install the engine block heater plug, if equipped.
30. Install the inner air deflector.
31. Install the eight torque converter nuts.
32. Install the cover.
33. Install the six lower transmission to engine bolts.
34. Install the Three-Way Catalytic (TWC) converter. .
35. Connect the generator electrical cable.
36. Connect the starter motor electrical connectors.
37. Install the cover.
38. Install the starter motor ground cable.
39. Connect the steering coupling.
40. Install the steering shaft bolt.
41. Connect the rack and pinion steering unit electrical connectors and install a tie-strap.
42. Install the retaining bolt for the high pressure power steering line bracket.
43. Install the hydraulic cooling fan return line to the RH frame rail.
44. Install the shift cable bracket.
45. Reclip the shift cable to the bracket.
46. Connect the shift cable to the shifter.
47. Install the driveshaft. For additional information, refer to «DRIVE SHAFTS»(ref-154077) .
48. Connect the A/C low pressure line.
49. Connect the A/C high pressure line.
50. Install the center splash shield.
51. Install the LH and the RH splash shields.
52. Install the LH and the RH lower strut mount bolts.
53. Install the LH and the RH ball joints to the spindles and install the nuts.
54. Install the LH and the RH sway bar lower nuts.
55. Install the LH and the RH brake calipers.
56. Position the LH and the RH anti-lock brake sensor harness and reclip to the brake hoses.
57. Connect the LH and the RH anti-lock brake sensor electrical connectors.
58. Install the LH and the RH inner splash shields.
59. Install the front wheels and tires.
60. Clip the harness to the radiator support and connect the water valve electrical connector.
61. Connect the hoses to the water control valve.
62. Connect the cooling fan hoses and install the hydraulic cooling fan reservoir.
63. Connect the connectors.
64. Install the fresh air filter panel. Position the panel. Install the nuts. Install the pin-type retainer.
65. Connect the powertrain bulkhead electrical connectors.
66. Install the fresh air filter housing.
67. Install the fresh air filter.
68. Connect the ground strap.
69. Connect the accelerator cable and the speed control cable.
70. Connect the degas bottle hose.
71. Install the bracket. Install the bracket. Install the seven bolts and one nut. Install the windshield washer hose.
72. Reclip the hose.
73. Install the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .
74. Connect the main vacuum supply hose.
75. Connect the VMV. Vacuum hose. Canister purge valve.
76. Install the VMV cover.
77. Connect the fuel line. For additional information, refer to «FUEL SYSTEM»(ref-142371-S41650265912002073100000) .
78. Connect the power steering pump reservoir hoses and install the power steering pump reservoir.
79. Attach the power steering return line to the brake lines.
80. Connect the A/C pressure switch electrical connector.
81. Install the two upper radiator support brackets.
82. Install the upper radiator sight shield.
83. Fill the engine with clean engine oil.
84. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204581) .
85. Install the air cleaner assembly and outlet pipe.
86. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .
87. Fill the power steering reservoir to the correct level. For additional information, refer to «POWER STEERING»(ref-204555) .
88. Fill and bleed the hydraulic cooling fan. For additional information, refer to «ENGINE COOLING»(ref-204560) .
89. Charge the A/C system. For additional information, refer to «GENERAL SERVICING PROCEDURES»(ref-156625) .