Engine: Other Lincoln Aviator I

Code Information

The engine code information label, located on the side of the valve cover and the front side of the valve cover, contains the following

1. Engine build date
2. Engine plant code
3. Engine code

Induction System

The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion in the cylinders. The eight solenoid-operated fuel injectors

1. are mounted in the lower intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. are connected in series with the fuel pressure sensor.
5. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank. A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor
6. is positioned upstream from the fuel injectors on the fuel injection supply manifold.

Valve Train

The valve train operates as follows

1. Ball-tip hydraulic lash adjusters provide automatic lash adjustment.
2. Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.

Positive Crankcase Ventilation System

All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.

Oil Pump

The lubrication system of the 4.6L (4V) engine is designed to provide optimum oil flow to critical components of the engine through it's entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure, both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Cooling System

The engine cooling system includes the following

1. Radiator
2. Water pump
3. Electric cooling fan motor and fan blade
4. Degas bottle, which aids in maintaining the correct volume of engine coolant
5. Thermostat
6. Upper radiator hose
7. Lower radiator hose
8. Heater hose

Drive Belt System

The 4.6L (4V) DOHC engine is equipped with a serpentine drive belt. To make sure of maximum life, install a new drive belt of the same type as originally installed.

1. The accessories mounted on the front of the engine are belt-driven by the crankshaft.
2. The serpentine drive belt is routed over each accessory pulley, driven by the crankshaft pulley bolted to the crankshaft.

Scheme 5

The accessory drive

1. has a single serpentine drive belt (six ribs).
2. has an automatic tensioner.
3. is not adjustable.

The engine emission control system consists of the

1. positive crankcase ventilation (PCV) system.
2. exhaust gas recirculation (EGR) system.

Scheme 6

The Vehicle Emission Control Information (VECI) decal shows

1. components of the emission control system.
2. the correct vacuum hose routing.
3. the color stripe of the vacuum hoses.

The PCV system uses intake manifold vacuum to ventilate the crankcase and return the fumes to the intake manifold for combustion.

Scheme 7

Refer to ENGINE SYSTEM - GENERAL INFORMATION .

Scheme 8

Scheme 9

Scheme 10

1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply: The EGR system returns a portion of the exhaust gas to the intake manifold to reduce the combustion temperature. This results in lower nitrous oxide formation. The powertrain control module (PCM) controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to the exhaust manifold tube and sends a signal to the powertrain control module. The PCV valve: controls the amount of ventilating air and blow-by gases going to the intake manifold. prevents a backfire from reaching the crankcase. The EGR system module to exhaust manifold tube: connects the exhaust manifold to the EGR valve. The EGR system module transducer: monitors the EGR system module flow rate through the EGR to exhaust manifold tube. sends an EGR system module flow rate signal to the powertrain control module. The EGR vacuum regulator solenoid uses input from the powertrain control module to change the EGR system module operation.
3. Inspect for drive belt cracking/chunking/wear.
4. If the concerns remain after inspection, determine the symptoms. GO to «SYMPTOM CHART»(ref-193002-S09925539092005092300000) . Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. A new drive belt should be installed if chunking occurs.
5. If the concern(s) remains after inspection, determine the symptoms. GO to «SYMPTOM CHART»(ref-193002-S09925539092005092300000) .

Scheme 11

Scheme 12

Drive Belt - Misalignment

Note. Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use.

Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt.

With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises.

If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected.

1. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as necessary.
2. Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck belt tracking.
3. Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking.

Belt Tensioner

The automatic drive belt tensioner can be checked as follows

Scheme 13

1. To remove individual components, carry out only the listed steps.

Scheme 14

Scheme 15

1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation. Engine Emission Control Refer to «SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE»(ref-152182) .
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.

Item 1: Accessory Drive Belt Removal Note

Scheme 16

1. Rotate the belt tensioner clockwise and remove the accessory drive belt.

Scheme 17

Scheme 18

Scheme 19

1. Remove the engine cover.
2. Remove the RH front wheel and tire assembly. For additional information, refer to «SUSPENSION SYSTEM»(ref-192997) .
3. To remove individual components, carry out only the listed steps.
4. Remove the components in the order indicated in the following illustration.
5. To install, reverse the removal procedure.

Item 7: EGR Valve System Module Gasket Removal Note

1. Carefully clean the EGR sealing surfaces.

Scheme 20

1. Remove the engine cover.
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.

Item 3: PCV Valve Removal Note

1. Twist the PCV valve counterclockwise to remove from valve cover.

Scheme 21

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-193003) .
3. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-156725-S30541018892003072500000) .
4. Remove the alternator. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
5. Remove the air cleaner outlet pipe.
6. Remove the exhaust gas recirculation (EGR) system module. For additional information, refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE»(ref-193002-S30509002272005092300000) .
7. Remove the components in the order indicated in the following illustration.
8. To install, reverse the removal procedure.

Items 18 and 19: Upper Intake Manifold Fasteners Installation Note

Scheme 22

1. Tighten the bolts and studs in the sequence shown to 10 Nm (89 lb-in).

Scheme 23

Scheme 24

1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-193002-S10075151602005092300000) .
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.

Item 16: Fuel Hose Spring Lock Coupling Removal Note

Scheme 25

Scheme 26

Scheme 27

1. Install the special tool.
2. Press the special tool into the open end of the cage.
3. Separate the coupling.

Item 17: Lower Intake Manifold Bolts Installation Note

Scheme 28

1. Hand-start all fasteners.
2. Torque all fasteners in the sequence shown in the illustration to 10 Nm (89 lb-in).

Scheme 29

Scheme 30

1. Remove the air intake assembly.
2. Remove the ignition coils. For additional information, refer to «IGNITION COIL-ON-PLUG & SPARK PLUG»(ref-156725-S27172701912003072800000) . CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.

Item 5: Valve Cover Installation Note

1. Apply a minimum of 8 mm (0.32 in) diameter drop of sealant to the front cover gasket intersection.

Item 3: Valve Cover Bolts Installation Note

Scheme 31

1. Tighten the bolts and studs in the sequence shown to 10 Nm (89 lb-in).

Scheme 32

Scheme 33

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-193003) .
2. Remove the air intake assembly.
3. Remove the heated PCV valve. For additional information, refer to «POSITIVE CRANKCASE VENTILATION (PCV) VALVE»(ref-193002-S08326274052005092300000) .
4. Remove the ignition coils. For additional information, refer to «IGNITION COIL-ON-PLUG & SPARK PLUG»(ref-156725-S27172701912003072800000) . CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
5. Remove the components in the order indicated in the following illustration.
6. To install, reverse the removal procedure.

Item 6: Valve Cover Installation Note

1. Apply a minimum of 8 mm (0.32 in) diameter drop of sealant to the front cover gasket intersection.

Item 4: Valve Cover Bolts Installation Note

Scheme 34

1. Tighten the bolts and studs in the sequence shown to 10 Nm (89 lb-in).

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT, TENSIONER AND PULLEY»(ref-193002-S28069886252005092300000) .
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.

Item 3: Crankshaft Pulley Removal Note

Scheme 39

1. Using the special tool, remove the crankshaft pulley.

Item 4: Crankshaft Front Seal Removal Note

Scheme 40

1. Using the special tool, remove the front cover seal.

Item 4: Crankshaft Front Seal Installation Note

Scheme 41

1. Lubricate the front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal.

Item 3: Crankshaft Pulley Installation Note

Scheme 42

1. Install the crankshaft pulley within four minutes of applying silicone gasket and sealant to the Woodruff key slot.
2. Using the special tool, install the crankshaft pulley.

Item 1: Crankshaft Pulley Bolt Installation Note

1. Tighten the bolt in four stages: Stage 1: Tighten the bolt to 90 Nm (66 lb-ft) Stage 2: Loosen the bolt one full turn. Stage 3: Tighten the bolt to 50 Nm (37 lb-ft). Stage 4: Tighten the bolt an additional 90 degrees without exceeding 200 Nm (148 lb-ft).

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. Drain the engine oil.
3. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-193002-S06352792322005092300000) .
4. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-193003) .
5. To remove individual components, carry out only the individual steps.
6. Remove the components in the order indicated in the following illustration.
7. Remove the components in the order indicated in the following illustration.
8. Remove the components in the order indicated in the following illustration.
9. Remove the components in the order indicated in the following illustration.
10. Remove the components in the order indicated in the following illustration.
11. Remove the components in the order indicated in the following illustration.

Scheme 52

Item 1: Accessory Drive Belt Removal Note

Scheme 53

1. Rotate the belt tensioner clockwise and remove the accessory drive belt.

Item 37: Crankshaft Pulley Removal Note

Scheme 54

1. Using the special tool, remove the crankshaft pulley.

Item 38: Crankshaft Seal Removal Note

Scheme 55

1. Using the special tool, remove the crankshaft seal.

Item 39: Engine Front Cover Removal Note

Scheme 56

Scheme 57

1. Remove the four oil pan-to-engine front cover bolts.
2. Remove the fasteners and the engine front cover.
3. Remove and discard the gaskets, clean and inspect the sealing surfaces.

Items 42-47: Timing Chain Tensioner Removal Note

Scheme 58

Scheme 59

1. Using the special tool, position the crankshaft with the keyway at the 12 o'clock position.
2. Install the special tool.
3. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.

Items 41-78: Timing Drive Components Installation Note

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. Install the tensioners.
2. Install the camshaft sprockets and chain as an assembly.
3. Install the special tool.
4. Install the camshaft spacer, washer and bolt, and hand-tighten the bolt.
5. Install the camshaft gear, washer and bolt, and hand-tighten the bolt.
6. Tighten the bolts in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
7. Compress the tensioner plunger, using a soft-jawed vise.
8. Install a retaining clip on the tensioner to hold the plunger in during installation. Remove the tensioner from the vise.
9. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
10. Install the timing chain guides.
11. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
12. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
13. Remove the special tool.
14. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
15. Install the LH timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
16. Position the LH timing chain tensioner arms on the dowel pin and install the LH timing chain tensioner.
17. Remove the retaining clips from the LH timing chain tensioner.
18. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
19. Install the RH timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
20. Position the RH timing chain tensioner arms on the dowel pin and install the RH timing chain tensioner.
21. Remove the retaining clips from the RH timing chain tensioner.
22. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.

Item 39: Engine Front Cover Installation Note

Scheme 76

Scheme 77

1. Apply sealant in the locations shown.
2. Install the engine front cover seals and the engine front cover, and tighten the fasteners in the sequence shown.
3. Tighten the bolts in the sequence shown in three stages: Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.

Item 38: Crankshaft Seal Installation Note

Scheme 78

Scheme 79

1. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft seal.

Items 35-37: Crankshaft Pulley Installation Note

Scheme 80

1. Apply sealant to the Woodruff key slot on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install the bolt and the washer. Tighten the bolt in four stages: Stage 1: Tighten the bolt to 90 Nm (66 lb-ft). Stage 2: Loosen the bolt one full turn. Stage 3: Tighten the bolt to 50 Nm (37 lb-ft). Stage 4: Tighten the bolt an additional 90 degrees.

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Remove the engine front cover, timing gears, chain and tensioners. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-193002-S18500445112005092300000) .
2. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-193002-S36245742412005092300000) and «VALVE COVER RH»(ref-193002-S38099805952005092300000) .
3. Remove the roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-193002-S06352792322005092300000) .
4. Remove the spark plugs.
5. To remove individual components, carry out only the listed steps.
6. Remove the components in the order indicated in the following illustration.
7. To install, reverse the removal procedure.

Items 1-4: Exhaust Valve Spring Retainer Keys, Valve Springs and Valve Seals Removal Note

Note. Carry out the following steps for each cylinder requiring service.

Scheme 85

Scheme 86

1. Use compressed air in the cylinder to be serviced to hold both valves in position.
2. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
3. Using the special tool, compress the exhaust valve spring. Remove the exhaust valve spring retainer keys.
4. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal.

Items 5-8: Intake Valve Spring Retainer Keys, Valve Springs and Valve Seals Removal Note

Note. Carry out the following steps for each cylinder requiring service.

Scheme 87

Scheme 88

1. Use compressed air in the cylinder to be serviced to hold both valves in position.
2. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
3. Using the special tool, compress the intake valve spring. Remove the intake valve spring retainer keys.
4. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal.

Items 11-9: Camshaft Bearing Caps Installation Note

1. Install the camshaft bearing caps and tighten the fasteners in the sequence shown.

Items 8-5: Intake Valve Seals, Valve Spring and Valve Spring Retainer Keys Installation Note

Note. Carry out the following steps for each cylinder requiring service.

Scheme 89

Scheme 90

Scheme 91

1. Using the special tools, install the new intake valve stem seals. Repeat this step to install all necessary intake valve stem seals.
2. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
3. Position the intake valve spring and the spring retainer over the intake valve stem and valve seal.
4. Using the special tool, compress the intake valve spring. Install the intake valve spring retainer keys.
5. Remove the compressed air hose from the cylinder.

Items 4-1: Exhaust Valve Seals, Valve Springs and Valve Spring Retainer Keys Installation Note

Note. Carry out the following steps for each cylinder requiring service.

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Using the special tools, install the new exhaust valve stem seals. Repeat this step to install all necessary exhaust valve stem seals.
2. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
3. Position the exhaust valve spring and the spring retainer over the exhaust valve stem and valve seal.
4. Using the special tool, compress the exhaust valve spring. Install the exhaust valve spring retainer keys.
5. Remove the compressed air hose from the cylinder.

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Remove the right and left valve covers, as necessary. For additional information, refer to «VALVE COVER RH»(ref-193002-S38099805952005092300000) or «VALVE COVER LH»(ref-193002-S36245742412005092300000) .
2. To remove individual components, carry out only the listed steps.
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.

Items 1 and 3: Camshaft Roller Followers Removal Note

Scheme 101

1. Using the special tool, partially compress the intake valve spring and remove the camshaft roller follower.
2. Using the special tool, partially compress the exhaust valve spring and remove the camshaft roller follower.

Items 2 and 4: Hydraulic Lash Adjusters Removal Note

1. Remove the hydraulic lash adjusters.

Items 3 and 1: Camshaft Roller Followers Installation Note

Scheme 102

1. Using the special tool, partially compress the exhaust valve spring and install the camshaft roller follower.
2. Using the special tool, partially compress the intake valve spring and install the camshaft roller follower.

Scheme 103

1. With the vehicle in NEUTRAL position on a hoist.
2. Remove the steering intermediate shaft. For additional information, refer to «STEERING SYSTEM»(ref-193001) .
3. Remove the LH front wheel and tire. For additional information, refer to «SUSPENSION SYSTEM»(ref-192997) .
4. Remove the LH front inner fenderwell. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .
5. Remove the components in the order indicated in the following illustration.
6. To install, reverse the removal procedure.

Scheme 104

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the RH front wheel and tire. For additional information, refer to «SUSPENSION SYSTEM»(ref-192997) .
3. Remove the RH front inner fenderwell. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .
4. Remove the components in the order indicated in the following illustration.
5. To install, reverse the removal procedure.

Scheme 105

1. With the vehicle in NEUTRAL, position on a hoist.
2. Drain the coolant. For additional information, refer to «ENGINE COOLING»(ref-193003) .
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.

Scheme 106

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.

Scheme 107

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the steering intermediate shaft. For additional information, refer to «STEERING SYSTEM»(ref-193001) .
3. Remove the LH front wheel and tire. For additional information, refer to «SUSPENSION SYSTEM»(ref-192997) .
4. Remove the LH front inner fenderwell. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .
5. Remove the components in the order indicated in the following illustration.
6. To install, reverse the removal procedure.

Scheme 108

Scheme 109

Scheme 110

1. With the vehicle in NEUTRAL position on a hoist.
2. Drain the engine oil.
3. Remove the front stabilizer bar. For additional information, refer to «SUSPENSION SYSTEM»(ref-192997) .
4. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER, TIMING GEARS, CHAIN AND TENSIONERS»(ref-193002-S18500445112005092300000) .
5. To remove individual components, carry out only the listed steps.
6. Remove the components in the order indicated in the following illustration.
7. To install, reverse the removal procedure.

Item 1: Front Axle Bolts Removal Note

1. Support the front axle using an appropriate jack. Lower the front axle approximately 150 mm (6 in).

Item 6: Oil Pan Removal Note

1. Clean the sealing surfaces with metal surface cleaner.

Item 12: Oil Pump Installation Note

1. Align the inner rotor of the oil pump assembly to align with the flats on the crankshaft, and slide the oil pump toward the block until it is seated against the block.
2. Rotate the oil pump assembly to align with the bolt holes.

Item 10: Oil Pump Screen and Pickup Tube Installation Note

1. Install O-ring seal.

Item 6: Oil Pan Installation Note

Scheme 111

1. Tighten the bolts in the sequence shown in three stages: Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-193005) .
2. Remove the oil pan. For additional information, refer to «OIL PAN, OIL PUMP, OIL PUMP SCREEN AND PICKUP TUBE»(ref-193002-S39554863692005092300000) .
3. Remove the components in the order indicated in the following illustration.
4. To remove individual components, carry out only the listed steps.
5. To install, reverse the removal procedure.

Item 4: Crankshaft Rear Oil Slinger Removal Note

Scheme 116

1. Using the special tools, remove the oil slinger.

Item 5: Crankshaft Rear Oil Seal Removal Note

Scheme 117

1. Using the special tools, remove the crankshaft rear oil seal.

Item 7: Crankshaft Rear Oil Seal Retainer Plate Installation Note

1. Clean and inspect the mating surface.
2. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.

Item 6: Crankshaft Rear Oil Seal Retainer Bolts Installation Note

Scheme 118

1. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in.)

Item 5: Crankshaft Rear Oil Seal Installation Note

Scheme 119

1. Using the special tools, install the crankshaft rear oil seal. Lubricate the crankshaft rear oil seal with motor oil before installation.

Item 4: Crankshaft Rear Oil Slinger Installation Note

Scheme 120

1. Using the special tool, install the crankshaft rear oil slinger.

Scheme 121

Scheme 122

Scheme 123

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-193003) .
3. Remove the alternator. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
4. Remove the wiper cowling. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .
5. Remove the exhaust gas recirculation (EGR) system module and the tube assembly. For additional information, refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE»(ref-193002-S30509002272005092300000) .
6. To remove individual components, carry out only the listed steps.
7. Remove the components in the order indicated in the following illustration.
8. To install, reverse the removal procedure.

Item 1: Stabilizer Bar Bracket Bolts Removal Note

1. Reposition the stabilizer bar to gain clearance.

Item 2: Front Axle Bolts Removal Note

1. Support the axle using an appropriate jack. Lower the axle approximately 150 mm (6 in).

Item 7: Front Axle Bolts Removal Note

1. Raise the front axle into position and loosely install the bolts. Remove the jack.

Item 8: LH Engine Support Insulator Removal Note

Scheme 124

1. Lower the vehicle.
2. Install the special tools.
3. Raise the engine until the insulator can be removed.

Item 9: RH Engine Support Insulator Removal Note

Scheme 125

1. Lower the vehicle.
2. Install the special tools.
3. Raise the engine until the insulator can be removed.

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

1. Remove the engine. For additional information, refer to «ENGINE»(ref-193002-S04804878992005092300000) .
2. Remove the flexplate and the spacer plate.
3. Mount the engine on a suitable engine stand.
4. Remove the LH and RH engine mounts.
5. Remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished.
6. Remove the two bolts and the pin-type retainer from the power steering reservoir bracket.
7. Remove the power steering reservoir and bracket. Disconnect the hose from the power steering pump. Remove the bolt and the reservoir and bracket.
8. Disconnect the battery cable harness ground.
9. Disconnect the electrical connector and the battery cable from the alternator.
10. Disconnect the two retainers from the engine front cover studs.
11. Disconnect the two retainers from the A/C compressor.
12. Remove the bolt and the battery cable harness from the RH engine mount.
13. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.
14. Disconnect the vacuum harness from the intake manifold and remove the harness.
15. Remove the LH and RH coil covers.
16. Disconnect the RH and LH ignition coil electrical connectors.
17. Disconnect the radio interference capacitor electrical connector.
18. Disconnect the eight fuel injector electrical connectors.
19. Separate the fuel charging wiring harness retainers from the fuel injection supply manifold.
20. Disconnect the camshaft position (CMP) sensor electrical connector and the two retainers from the valve cover.
21. Disconnect the oil pressure sensor electrical connector.
22. Disconnect the pin-type retainers from the back of the engine in the locations shown.
23. Disconnect the knock sensor (KS) electrical connector and the pin-type retainer.
24. Disconnect the wiring harness retainer from the stud on the cylinder head.
25. Disconnect the intake manifold runner control (IMRC) electrical connector.
26. Disconnect the exhaust gas recirculation (EGR) system module tube nut from the exhaust manifold.
27. Disconnect the cylinder head temperature (CHT) sensor electrical connector and the two pin-type retainers.
28. Disconnect the positive crankcase ventilation (PCV) electrical connector.
29. Remove the PCV tube.
30. Disconnect the RH radio interference capacitor electrical connector and the pin-type retainer.
31. Disconnect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
32. Disconnect the two retainers from the RH valve cover studs.
33. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
34. Disconnect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.
35. Remove the upper radiator hose.
36. Remove the coolant bypass-to-thermostat housing hose.
37. Rotate the belt tensioner clockwise and remove the accessory drive belt.
38. Remove the bolts and the generator support bracket.
39. Remove the bolts and the generator.
40. Remove the crossover tube. Disconnect the coolant hose. Remove the retainers and the crossover tube.
41. Remove the eight ignition coils.
42. Remove the nut and the bolt from the oil level indicator tube and position the tube aside.
43. Remove the engine lifting eyes.
44. Remove the bolts and the LH valve cover.
45. Remove the coolant hose retainers from the RH valve cover.
46. Remove the bolts and the RH valve cover.
47. Remove the retainers and the upper-to-lower intake bracket.
48. Remove the bolts in the sequence shown and remove the upper and lower intake.
49. Remove the bolt and the coolant bypass tube.
50. Remove the exhaust manifolds. Remove the 16 nuts. Remove the exhaust manifolds. Remove the exhaust manifold gaskets.
51. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-211830) .
52. Remove the oil level indicator tube.
53. Remove the three remaining bolts and the power steering pump.
54. Install the special tool. Loosen the bolts.
55. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
56. Using the special tool to prevent the crankshaft pulley from turning, remove the pulley bolt.
57. Remove the bolt.
58. Using the special tool, remove the crankshaft vibration damper.
59. Using the special tool, remove the crankshaft front seal.
60. Remove the bolt and the belt idler pulley.
61. Remove the four front oil pan-to-timing cover bolts.
62. Remove the engine front cover fasteners in the sequence shown.
63. Remove the crankshaft position sensor pulse wheel.
64. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
65. Using the special tool, compress the intake valve spring and remove the roller follower.
66. Using the special tool, compress the exhaust valve spring and remove the roller follower.
67. Repeat the above steps to remove all the roller followers.
68. Remove the bolts and the RH and LH timing chain tensioners.
69. Remove the RH and LH timing chain tensioner arms.
70. Remove the RH and the LH timing chains and the crankshaft sprocket.
71. Remove the RH and LH timing chain guides.
72. Remove the hydraulic lash adjusters.
73. Remove the RH and LH cylinder heads. Discard the cylinder head bolts. Discard the cylinder head gaskets.
74. Clean and inspect the cylinder heads. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-211830) article.

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. Remove the transmission. For additional information, refer to «REMOVAL»(ref-193005-S27305657202005092300000) .
3. Remove the hood. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .
4. Remove the engine appearance cover.
5. Remove the air cleaner assembly.
6. Remove the evaporative emissions canister purge valve. For additional information, refer to «FUEL SYSTEM»(ref-193011) .
7. Remove the cooling module. For additional information, refer to «ENGINE COOLING»(ref-193003) .
8. Discharge and recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-193016) .
9. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM»(ref-193011) .
10. Remove the starter motor. For additional information, refer to «STARTERS»(ref-168133) .
11. Remove the components in the order indicated in the following illustration.
12. Remove the components in the order indicated in the following illustration.
13. Remove the components in the order indicated in the following illustration.
14. Remove the components in the order indicated in the following illustration.
15. Remove the components in the order indicated in the following illustration.
16. Remove the components in the order indicated in the following illustration.

Item 9: Engine Wiring Harness Removal Note

Scheme 194

1. Unclip the engine wiring harness retainers, remove the transmission wiring harness from the clips and position the engine wiring harness onto the engine.

Item 12: Accelerator Cable Bracket Bolts Removal Note

Scheme 195

1. Disconnect the accelerator cable and the speed control cable from the throttle cam.

Item 13: Accelerator Cable Bracket Removal Note

Scheme 196

1. Disconnect the speed control cable and the accelerator cable to the throttle cam.

Item 17: Coolant Hose Removal Note

Scheme 197

1. Unclip the hose retainers and position the coolant hoses aside.

Item 26: EGR System Module Vacuum Hoses and Electrical Connector Removal Note

Scheme 198

1. Disconnect the vacuum hoses and the electrical connector from the EGR system module.

Item 27: Fuel Hose Removal Note

Scheme 199

Scheme 200

Scheme 201

1. Install the special tool.
2. Press the special tool into the open end of the spring lock coupling cage.
3. Separate the fuel hose spring lock couplings.

Item 28: EGR System Module Tube Nut Removal Note

1. Loosen the nut connecting the tube to the exhaust manifold.

Item 67: Engine Removal Note

Scheme 202

1. Support the transmission with a suitable floor jack.
2. Install the right and left engine lifting eyes.
3. Install the special tool to a suitable engine lifting crane and remove the engine from the vehicle.

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

1. Remove the components in the order indicated in the following illustration.
2. Remove the components in the order indicated in the following illustration.
3. Remove the components in the order indicated in the following illustration.
4. Remove the components in the order indicated in the following illustration.
5. Remove the components in the order indicated in the following illustration.
6. Remove the components in the order indicated in the following illustration.
7. Remove the components in the order indicated in the following illustration.
8. Remove the components in the order indicated in the following illustration.
9. Remove the components in the order indicated in the following illustration.
10. Remove the components in the order indicated in the following illustration.
11. Remove the components in the order indicated in the following illustration.
12. Remove the components in the order indicated in the following illustration.
13. Remove the components in the order indicated in the following illustration.

Item 4: Crankshaft Oil Slinger Disassembly Note

Scheme 220

1. Using the special tools, remove the crankshaft oil slinger.

Item 5: Crankshaft Rear Seal Disassembly Note

Scheme 221

1. Using the special tools, remove the crankshaft rear seal.

Item 8: Crankshaft Rear Seal Retainer Plate Disassembly Note

1. After retainer plate removal, mount the engine on an engine stand.

Items 38 and 39: Upper Intake Manifold Assembly Fasteners Disassembly Note

Scheme 222

1. Remove the upper intake manifold assembly bolts in the sequence shown.

Item 71: Crankshaft Damper Disassembly Note

Scheme 223

1. Using the special tool, remove the crankshaft vibration damper.

Item 107: Lower Intake Manifold Bolts Disassembly Note

Scheme 224

1. Remove the lower intake manifold assembly bolts in the sequence shown.

Item 148: Crankshaft Front Seal Disassembly Note

Scheme 225

1. Using the special tool, remove the crankshaft front seal.

Item 149: Engine Front Cover Disassembly Note

Scheme 226

1. Remove the engine front cover fasteners in the sequence shown.

Item 150: Camshaft Roller Followers Disassembly Note

Scheme 227

Scheme 228

1. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
2. Using the special tool, compress the intake valve spring and remove the roller follower.
3. Using the special tool, compress the exhaust valve spring and remove the roller follower.
4. Repeat the above steps to remove all the roller followers.

Scheme 229

Scheme 230

Scheme 231

1. Remove the components in the order indicated in the following illustrations.
2. To assemble, reverse the disassembly procedure.

Scheme 232

Item 1: Camshaft Roller Followers Disassembly Note

Scheme 233

Scheme 234

1. Using the special tool, partially compress the intake valve spring and remove the camshaft roller follower.
2. Using the special tool, partially compress the exhaust valve spring and remove the camshaft roller follower.

Item 2: Hydraulic Lash Adjusters Disassembly Note

1. Remove the hydraulic lash adjusters.

Items 3-6: Valve Spring Retainer Keys, Valve Springs and Valve Seals Disassembly Note

Scheme 235

Scheme 236

Scheme 237

Scheme 238

1. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
2. Using the special tool, compress the exhaust valve spring. Remove the exhaust valve spring retainer keys.
3. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal.
4. Repeat the above three steps and remove all of the exhaust valve spring assemblies.
5. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
6. Using the special tool, compress the intake valve spring. Remove the intake valve spring retainer keys.
7. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal.
8. Repeat the above three steps to remove all of the intake valve spring assemblies.

Items 20-18 Camshaft Bearing Caps Assembly Note

1. Install the camshaft bearing caps and tighten the fasteners in the sequence shown.

Items 6-3: Valve Seals, Valve Springs and Valve Spring Retainer Keys Assembly Note

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

1. Using the special tools, install the new intake valve stem seals. Repeat this step to install all the intake valve stem seals.
2. Using the special tools, install the new exhaust valve stem seals. Repeat this step to install all the exhaust valve stem seals.
3. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
4. Position the exhaust valve spring and the spring retainer over the exhaust valve stem and valve seal.
5. Using the special tool, compress the exhaust valve spring. Install the exhaust valve spring retainer keys.
6. Repeat the above three steps to install all of the exhaust valve spring assemblies.
7. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
8. Position the intake valve spring and the spring retainer over the intake valve stem and valve seal.
9. Using the special tool, compress the intake valve spring. Install the intake valve spring retainer keys.
10. Repeat the above three steps to install all of the intake valve spring assemblies.

Item 2: Hydraulic Lash Adjusters Assembly Note

Scheme 247

1. Install the hydraulic lash adjusters in their original positions.

Item 1: Camshaft Roller Followers Assembly Note

Scheme 248

Scheme 249

1. Using the special tool, partially compress the exhaust valve spring and install the camshaft roller follower.
2. Using the special tool, partially compress the intake valve spring and install the camshaft roller follower.

Scheme 250

Scheme 251

1. Remove the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Items 9 and 10: Piston and Connecting Rod Assembly Note

1. Position the connecting rod in the piston.

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Note. Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

1. Assemble the components in the order indicated in the following illustration.
2. Assemble the components in the order indicated in the following illustration.
3. Assemble the components in the order indicated in the following illustration.
4. Assemble the components in the order indicated in the following.
5. Assemble the components in the order indicated in the following illustration.
6. Assemble the components in the order indicated in the following illustration.
7. Assemble the components in the order indicated in the following illustration.
8. Assemble the components in the order indicated in the following illustration.
9. Assemble the components in the order indicated in the following illustration.
10. Assemble the components in the order indicated in the following illustration.
11. Assemble the components in the order indicated in the following illustration.
12. Assemble the components in the order indicated in the following illustration.
13. Assemble the components in the order indicated in the following illustration.

Item 6: Crankshaft Main Lower Bearing Thrust Washer Assembly Note

1. Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.

Items 7-10: Crankshaft Main Bearing Cap Assembly Note

Scheme 269

Scheme 270

Scheme 271

1. Loosely install the main bearing caps and bolts.
2. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
3. Tighten the bolts in the sequence shown in four stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten to 40 Nm (30 lb-ft). Stage 4: Tighten an additional 90 degrees.

Item 11: Crankshaft Main Bearing Cap Side Bolts Assembly Note

Scheme 272

1. Install and tighten the cross-mounted bolts in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
2. Check the crankshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Items 13 and 16: Piston and Connecting Rod Assembly Note

Scheme 273

1. Using the special tool, push the pistons through the top of the cylinder block.
2. Using the special tool, install the connecting rod assemblies.
3. Install the connecting rod bearing caps and bolts and tighten in three stages: Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 45 Nm (33 lb-ft). Stage 3: Tighten an additional 90 degrees.
4. Check the connecting rod bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Items 20 and 23: Cylinder Head Bolt Assembly Note

Scheme 274

1. Tighten the cylinder head bolts in six stages in the sequence shown: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Loosen the bolts a minimum of one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.

Item 35-37: Crankshaft Gear and LH/RH Timing Chain Assembly Note

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

1. Install the crankshaft sprocket with the flange facing forward.
2. Using the special tool, position the crankshaft. Remove the special tool.
3. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
4. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
5. Install the LH and RH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
6. Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.

Items 39 and 42: LH/RH Timing Chain Tensioner Assembly Note

Scheme 280

1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.

Item 44: Crankshaft Sensor Ignition Pulse Ring Assembly Note

Scheme 281

1. As a post-check, verify correct alignment of all timing marks.
2. Position the crankshaft sensor ring on the crankshaft.

Item 45: Camshaft Roller Followers Assembly Note

Scheme 282

Scheme 283

1. Position the piston of the cylinder in which the roller followers are being installed at the bottom of the stroke, and camshaft lobe at the base circle.
2. Using the special tool, compress the intake valve spring and install the roller follower.
3. Using the special tool, compress the exhaust valve spring and install the roller follower.
4. Repeat the above steps to install all of the roller followers.

Item 48: Oil Pan Bolts Assembly Note

Scheme 284

1. Tighten the bolts in the sequence shown. Tighten to 20 Nm (15 lb-ft). Rotate an additional 60 degrees.

Item 49: Engine Front Cover Assembly Note

Scheme 285

1. Apply silicone gasket and sealant in the locations shown.
2. Install the engine front cover.
3. Tighten the four oil pan bolts in the sequence shown: Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.

Item 50: Crankshaft Front Seal Assembly Note

Scheme 286

Scheme 287

1. Lubricate the front oil seal and the engine front cover with clean engine oil.
2. Using the special tools, install the front oil seal.

Items 64-66 and 73-75: Valve Rocker Arm Cover Assembly Note

1. Apply silicone gasket and sealant in the locations shown.
2. Install the valve rocker arm covers and tighten the bolts in the sequence shown.

Item 87: Intake Manifold Bolts Assembly Note

Scheme 288

1. Hand-start all fasteners.
2. Tighten all fasteners in the sequence shown to 10 Nm (89 lb-in).

Items 123 and 124: Crankshaft Vibration Damper and Bolt Assembly Note

Scheme 289

Scheme 290

Scheme 291

1. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install the crankshaft pulley and tighten the bolt in four stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen the bolt one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

Items 155 and 156: Upper Intake Manifold Assembly Note

Scheme 292

1. Hand-start all fasteners.
2. Tighten all fasteners in the sequence shown to 10 Nm (89 lb-in).

Items 186-188: Crankshaft Rear Seal Retainer Plate and Bolts, Oil Pan Bolts Assembly Note

Scheme 293

1. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface. Also apply a bead of silicone gasket and sealant at the junction where the cylinder block, oil pan and rear oil seal retainer plate meet.
2. Install the rear oil seal retainer plate. Tighten the bolts in the sequence shown. Tighten bolts 1-6 to 10 Nm (89 lb-in). Hand-tighten bolts 7 and 8. Tighten bolts 7 and 8 to 20 Nm (15 lb-ft). Tighten bolts 7 and 8 an additional 60 degrees.

Item 189: Crankshaft Rear Seal Assembly Note

Scheme 294

1. Using the special tool, install the crankshaft rear main seal.

Item 190: Crankshaft Oil Slinger Assembly Note

Scheme 295

1. Using the special tools, install the crankshaft oil slinger.

Item 193: Flexplate Bolts Assembly Note

Scheme 296

1. Install the flywheel bolts in the sequence shown.

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

1. Install the components in the order indicated in the following illustration.
2. Install the components in the order indicated in the following illustration.
3. Install the components in the order indicated in the following illustration.
4. Install the components in the order indicated in the following illustration.
5. Install the components in the order indicated in the following illustration.
6. Install the components in the order indicated in the following illustration.
7. Install the starter motor. For additional information, refer to «STARTERS»(ref-168133) .
8. Install the cooling module. For additional information, refer to «ENGINE COOLING»(ref-193003) .
9. Install the evaporative emissions canister purge valve. For additional information, refer to «FUEL SYSTEM»(ref-193011) .
10. Install the air cleaner assembly.
11. Fill the engine with clean engine oil.
12. Connect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
13. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-193003) .
14. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-193016) .
15. Install the engine appearance cover.
16. Install the hood. For additional information, refer to «BODY SYSTEM - EXTERIOR»(ref-193027) .

Item 1: Engine Installation Note

Scheme 305

1. Using a suitable lifting crane, install the engine in the vehicle.

Item 18: Power Steering Pressure Hose Fitting Installation Note

Scheme 306

1. Using the special tool, install a new seal on the power steering pressure hose fitting.

Item 40: EGR System Module Tube Nut Installation Note

1. Tighten both fittings to 40 Nm (30 lb-ft).

Item 46: EGR System Module Vacuum Hose and Electrical Connector Installation Note

Scheme 307

1. Connect the vacuum hoses and the electrical connector to the EGR system module.

Item 50: Coolant Hose Installation Note

Scheme 308

1. Install the coolant hoses into the retaining clips.

Items 55 and 56: Accelerator Cable Bracket and Bolts Installation Note

Scheme 309

1. Connect the speed control cable and the accelerator cable to the throttle cam.

Item 59: Engine Wiring Harness Installation Note

Scheme 310

1. Position the transmission wiring harness into the engine wiring harness and mount the engine wiring harness to the cowl.