Engine - 3.0L (4V): Other Lincoln LS I рестайлинг

Engine Code Information

The engine code information label is located on the front fender. 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 ENGINE SYSTEM-GENERAL INFORMATION .

Induction System

The fuel needed for burning in the cylinders is provided by a returnless, sequential multiport fuel injection (SFI).

1. Fuel is supplied from the vehicle fuel tank by a high-pressure electric fuel pump mounted in the fuel tank.
2. The fuel is filtered and sent to the fuel injection supply manifold.
3. Fuel pressure is regulated by modulating pump output based upon readings from the fuel pressure sensor, located on the fuel rail.
4. Fuel is metered into the intake air stream in accordance with engine by 6 solenoid-operated fuel injectors mounted in the lower intake manifolds.
5. The 6 fuel injectors are mounted above the intake valves and connected in series with the fuel pressure regulator.

Crankshaft

The crankshaft is supported on the bottom of the cylinder block by 4 steel-backed, over-plated, aluminum crankshaft main bearings.

To provide smooth engine operation, the piston crankpins are positioned to provide a power impulse every 120 degrees of crankshaft rotation. The spacing provides smooth and quiet operation.

Two sprockets and timing chains connect the crankshaft with the camshafts and provide a 2:1 drive ratio.

Camshaft

The camshafts

1. Are supported on 4 bearing inserts.
2. Thrust loads and end play are limited by a camshaft thrust plate.

Cylinder Head

The spark plug is installed in the center of the fuel/air roof-shaped combustion chamber to ignite the mixture in the combustion chamber. The central location of the spark plug causes the flame front to be evenly spread across the chamber, which also reduces spark knock.

Valve Train

Both camshafts are driven by a shared timing chain, and operate 4 valves per cylinder by means of a selective shim sitting on the top of a tappet. One spring on each valve is used to close the valve. The adjusting shims in the valve tappets can be changed to correct the valve clearance. These are available in 44 different thicknesses. The shim thickness is ink printed on the back of the shim. A high degree of accuracy is required during adjusting to avoid repeated changing of the shims. The camshaft cams run concentrically on the valve tappets. At engine speeds of about 3,000 RPM this causes the tappets to rotate, and they in turn transfer the rotation to the valves. This valve rotation is required because it produces an even valve seating and prevents the valves from wearing in a certain position which could cause them to leak.

Variable Camshaft Timing (VCT)

The VCT system changes camshaft timing dependent on engine speed, load and oil temperature. Oil pressure advances and retards camshaft timing to improve low and high speed engine performance, engine idle quality and exhaust emissions.

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 lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump. Generically this design is known as a G-rotor pump.

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 the crankshaft.

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.

1. Oil pump displacement has been selected to provide adequate volume so there is correct oil pressure both at hot idle and maximum speed.
2. Relief valve calibration protects the system from excessive pressure during high viscosity conditions, yet is designed to provide adequate connecting rod bearing lubrication under high temperature and high speed conditions.

Engine Cooling System

The engine is liquid-cooled by a centrifugal coolant pump driven through the front engine accessory drive by the crankshaft.

A thermostat is used to restrict coolant flow until the engine reaches normal operating temperature.

Oil Pan

The oil pan is cast aluminum and is attached to the cylinder block and transmission.

1. The oil pan acts as a reservoir holding lubricating oil that is pumped through the engine by the oil pump after start-up.

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. Coolant pump
2. A/C compressor
3. Generator
4. Drive belt tensioner
5. Drive belt idler pulleys
6. Crankshaft pulley
7. Power steering pump pulley

Scheme 109

Engine Emission Control

The engine emission control consists of the

1. Positive crankcase ventilation (PCV) system.
2. Exhaust gas recirculation (EGR) system module.

The Vehicle Emission Control Information (VECI) decal shows

1. the components of the emission control system.
2. the correct vacuum hose routing.

For additional information, refer to IDENTIFICATION CODES .

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

The PCV valve (3.0L only)

1. Controls the amount of ventilating air and blow-by gases going to the intake manifold.
2. Prevents a backfire from reaching the crankcase.

Scheme 110

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 system module. When the EGR valve opens, exhaust gas flows to the intake manifold. The differential pressure feedback sensor measures the flow through the EGR valve from the exhaust manifold tube and sends a signal to the PCM. A metering orifice in the EGR valve-to-exhaust manifold tube restricts the flow rate when the EGR valve is open.

Refer to ENGINE SYSTEM-GENERAL INFORMATION for basic mechanical concerns.

Refer to ENGINE SYSTEM-GENERAL INFORMATION for driveability concerns.

Belt Tensioner - Mechanical

The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.

1. With the engine OFF, check routing of the accessory drive belt. For additional information, refer to the «ACCESSORY DRIVE BELT»(ref-207552-S42233193472005113000000) in this section.
2. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt in the area of the tensioner.
3. Using the suitable, commercially available serpentine belt tensioner release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring.
4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Install a new accessory drive belt tensioner if necessary.
5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. Install a new accessory drive belt tensioner as necessary.
6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, install a new tensioner.

Belt Tensioner - Dynamics

The accessory drive belt tensioner can be checked dynamically as follows

1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the air conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without air conditioning clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner.

Refer to ENGINE SYSTEM-GENERAL INFORMATION .

Valve Clearance Check

1. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-207552-S00481879552005113000000) or Valve Cover RH in this section.
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-207552-S40657616862005113000000) in this section.
5. To assemble, reverse the inspection procedure.

Scheme 111

Scheme 112

Scheme 113

1. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.
2. Use a feeler gauge to measure each valve clearance and record its location.
3. Remove the camshafts. For additional information, refer to «CAMSHAFT, VALVE SPRINGS AND VALVE SEALS»(ref-207552-S21649349762005113000000) in this section.
4. Remove the shims.
5. Select shims and mark the installation location.
6. Install new shims.
7. Install the camshaft. For additional information, refer to «CAMSHAFT, VALVE SPRINGS AND VALVE SEALS»(ref-207552-S21649349762005113000000) in this section.
8. Measure the new valve clearances.
9. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.

Scheme 114

1. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. COMPONENT STEPS SPECIFICATION Component Steps Accessory drive belt 1 Accessory drive belt tensioner 1-3 LH Accessory drive belt idler pulley 1, 4-5 RH Accessory drive belt idler pulley 1, 6-7
3. To install, reverse the removal procedure.

Item 1: Accessory Drive Belt Removal Note

1. Rotate the accessory drive belt tensioner counterclockwise to remove the accessory drive belt.

Item 1: Accessory Drive Belt Installation Note

1. Rotate the accessory drive belt tensioner counterclockwise to install the accessory drive belt.

Scheme 115

1. With the vehicle in neutral, position it on a hoist.
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. COMPONENT STEPS SPECIFICATION Component Steps Exhaust gas recirculation (EGR) valve system module 1-2, 4-7 Exhaust manifold-to-EGR valve tube 2-3
3. To install, reverse the removal procedure.

Step 7: EGR Valve System Module Gasket Installation Note

1. Clean the EGR valve system module gasket mating surfaces. Install a new gasket with the side with the raised circle facing the intake manifold.

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. With the vehicle in neutral, position it on a hoist.
2. Disconnect the battery ground cable.
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .
4. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
5. Remove the cowl vent screen. For additional information, refer to «EXTERIOR TRIM»(ref-207571) .
6. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table.
7. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table.
8. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table.
9. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table.

Item 7: Vacuum Hose Removal Note

Scheme 120

1. Remove the vacuum hoses from the mounting bracket.

Item 11: PCV Tube Removal Note

1. Position the PCV tube and coolant hose aside.

Items 24 and 25: Upper Intake Manifold and Mounting Bolts Installation Note

Scheme 121

1. Inspect the gaskets. Install new gaskets if necessary.
2. Position the upper intake manifold and install the bolts hand-tight.

Item 20: Fuel Pressure Sensor Shield Mounting Bolts Installation Note

Scheme 122

1. Install the fuel pressure sensor shield mounting bolts hand-tight. Tighten the upper intake manifold bolts in the sequence shown.

Item 11: PCV Tube Installation Note

1. Position the PCV tube and coolant hose to the intake manifold.

Item 7: Vacuum Hose Installation Note

Scheme 123

1. Clip the vacuum hoses into the mounting bracket.

Scheme 124

Material

MATERIAL SPECIFICATION CHART

Scheme 125

1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-207552-S01926490352005113000000) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM»(ref-207559) .
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Item 2: Fuel Hose Removal Note

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Remove the clip.
2. Install the special tool.
3. Close the special tool and push it into the open side of the cage.
4. Separate the fitting and remove the special tool.

Item 8: Lower Intake Manifold Gaskets Installation Note

1. Clean and inspect the lower intake manifold gaskets. Install new gaskets if necessary.

Item 6: Lower Intake Manifold Bolts Installation Note

Scheme 130

1. Tighten the lower intake manifold bolts in the sequence shown.

Item 2: Fuel Hose Installation Note

Scheme 131

1. Connect the spring lock coupling. Clean and inspect both coupling ends. Lubricate the O-rings with clean engine oil. Connect the coupling. Pull on the coupling to make sure it is fully engaged. Install the clip.

MATERIAL SPECIFICATION CHART

Scheme 132

Scheme 133

1. Disconnect the battery ground cable.
2. Remove the LH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555).
3. Remove the components in the order indicated in the following illustration and table. (Scheme 135)
4. Remove the components in the order indicated in the following illustration and table. (Scheme 136)
5. To install, reverse the removal procedure.

Items 16,17, and 18 Valve Cover, Valve Cover Bolts and Valve Cover Stud Bolts Installation Note

1. Clean the cylinder head-to-valve cover sealing surface.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealant to the cylinder head half-round surface and to the front cover-to-cylinder head joint face.
3. Install the LH valve cover, and tighten the bolts and stud bolts in the sequence shown. (Scheme 138)

MATERIAL SPECIFICATION CHART

Scheme 134

Scheme 135

1. Disconnect the battery ground cable.
2. Remove the RH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555).
3. Remove the components in the order indicated in the following illustration and table. (Scheme 139)
4. Remove the components in the order indicated in the following illustration and table. (Scheme 140)
5. To install, reverse the removal procedure.

Items 8, 9, and 10: Valve Cover, Valve Cover Stud Bolts and Valve Cover Bolts Installation Note

1. Clean the cylinder head-to-valve cover sealing surface.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealant to the cylinder head half-round surface and to the front cover-to-cylinder head joint face.
3. Install the RH valve cover, and tighten the bolts and stud bolts in the sequence shown. (Scheme 142)

Scheme 136

MATERIAL SPECIFICATION CHART

Scheme 137

1. With the vehicle in neutral, position it on a hoist.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT, TENSIONER AND PULLEY»(ref-207552-S23706520502005113000000) in this section.
3. Remove the front center splash shield.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Items 1 and 2: Crankshaft Pulley Bolt and Washer Removal Note

Scheme 138

1. Using the special tool to hold the crankshaft pulley, remove and discard the bolt.

Item 3: Crankshaft Pulley Removal Note

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

Item 4: Crankshaft Front Seal Removal Note

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

Item 4: Crankshaft Front Seal Installation Note

Scheme 139

1. Lubricate the inside diameter of the crankshaft front seal with clean engine oil.
2. Using the special tool, install the crankshaft front oil seal.

Item 3: Crankshaft Pulley Installation Note

1. Apply silicone gasket and sealant to the end of the keyway slot.
2. Using the special tool, install the crankshaft pulley.

Scheme 140

Items 1 and 2: Crankshaft Pulley Bolt and Washer Installation Note

Scheme 141

1. Using the special tool to hold the crankshaft pulley, install a new bolt. Tighten the bolt in four stages: Stage 1: Tighten to 120 N.m (89 lb-ft). Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

MATERIAL SPECIFICATION CHART

Scheme 142

Scheme 143

1. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-207552-S01143365862005113000000) in this section.
2. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-207552-S00481879552005113000000) in this section.
3. Remove the belt idler pulleys and the belt tensioner. For additional information, refer to «ACCESSORY DRIVE BELT, TENSIONER AND PULLEY»(ref-207552-S23706520502005113000000) in this section.
4. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-207554) .
5. Disconnect the upper radiator hose.
6. Remove the fuel tube bracket bolt.
7. Disconnect the lower radiator hose.
8. Remove the oil pan. For additional information, refer to «OIL PAN, OIL PUMP, OIL PUMP SCREEN AND PICKUP TUBE»(ref-207552-S22789148752005113000000) in this section.
9. Remove the power steering pump. For additional information, refer to «STEERING SYSTEM»(ref-207550) .
10. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT PULLEY AND CRANKSHAFT SEAL»(ref-207552-S13884443332005113000000) in this section.
11. Remove the components in the order indicated in the following illustration and table.
12. To install, reverse the removal procedure.

Items 5 and 6: Engine Front Cover and Engine Front Cover Gaskets Removal Note

1. Remove the fasteners and the engine front cover. Discard the gasket.

Scheme 144

Items 4-6: Engine Front Cover, Engine Front Cover Fasteners and Engine Front Cover Gaskets Installation Note

1. Clean the sealing surfaces on the engine and the engine front cover.
2. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealant to the areas indicated. Install a new gasket.
3. Position the front cover and tighten the bolts in the sequence shown.

MATERIAL SPECIFICATION CHART

Scheme 145

1. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-207552-S00481879552005113000000) in this section.
2. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-207552-S01143365862005113000000) in this section.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal order.

Items 1 and 3: Variable Camshaft Timing (VCT) System Oil Filter Cap Removal Note

1. Remove the bolt and the variable camshaft timing (VCT) solenoid.

Items 1 and 3: VCT System Oil Filter Cap Installation Note

1. Install VCT solenoid and the bolt.

Scheme 146

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

Scheme 147

1. With the vehicle in NEUTRAL, position on a hoist.
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .
3. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-207552-S00336559012005113000000) in this section.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.
6. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .

Items 2 and 3: Oil Cooler Bolt and Oil Cooler Installation Note

Scheme 148

1. Install the oil cooler and bolt finger-tight. Rotate the oil cooler clockwise until the locating pin hits the stop. Tighten the bolt to specification.

MATERIAL SPECIFICATION CHART

Scheme 149

1. Remove the LH engine mount. For additional information, refer to «ENGINE MOUNT - LH»(ref-207552-S13147762882005113000000) in this section.
2. If equipped, remove the oil cooler. For additional information, refer to «OIL COOLER»(ref-207552-S13701733422005113000000) in this section.
3. Drain the engine oil.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.
6. Fill the engine with clean engine oil.

Item 8: Oil Filter Adapter Installation Note

1. Clean and inspect the oil filter adapter and engine mating surfaces.

Items 4-7, Oil Filter Adapter Banjo Bolt, O-ring, Oil Filter Adapter Bolts, and Oil Filter Adapter Stud Bolt Installation Note

1. Install the O-ring seal on the banjo bolt and lubricate with clean engine oil.
2. Install the oil filter adapter banjo bolt, bolts, and studbolt hand tight. Tighten the bolts in six stages. Stage 1: Tighten the banjo bolt to 30 N.m (22 lb-ft). Stage 2: Tighten the bolts to 26 N.m (19 lb-ft). Stage 3: Tighten the studbolt to 25 N.m (18 lb-ft). Stage 4: Tighten the banjo bolt to 155 N.m (114 lb-ft). Stage 5: Tighten the bolts to 40 N.m (30 lb-ft). Stage 6: Tighten the bolts an additional 90 degrees.

Item 1: Oil Filter Installation Note

1. Using an oil filter strap wrench, install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Scheme 150

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

MATERIAL SPECIFICATION CHART

Scheme 151

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

Scheme 152

MATERIAL SPECIFICATION CHART

Scheme 153

Scheme 154

Scheme 155

1. With the vehicle in NEUTRAL position it on a hoist.
2. Remove the radiator upper sight shield.
3. Remove the air cleaner assembly. For additional information refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555).
4. Install the special tools.
5. Remove the steering gear. For additional information, refer to «STEERING SYSTEM»(ref-207550).
6. Remove the RH front splash shield, the LH front splash shield, and the front center splash shield.
7. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-164721).
8. Remove the A/C compressor. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561).
9. Drain the engine oil.
10. To remove individual components, only carry out the listed steps. COMPONENT STEPS SPECIFICATION CHART Component Steps Oil pan 1-5 Oil pump screen and pickup tube 1-9 Oil pump 1-11
11. Remove the components in the order indicated in the following illustration and table. (Scheme 182)
12. Remove the components in the order indicated in the following illustration and table. (Scheme 183)
13. To install, reverse the removal procedure.

Item 4: Oil Pan Removal Note

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

1. Remove the eight bolts and the two front I-braces.
2. Remove the LH lower control arm through-bolt.
3. Remove the RH lower control arm through-bolt.
4. Remove the LH and RH engine mount nuts.
5. Remove the LH subframe bolts.
6. Remove the RH subframe bolts.
7. Gently pry the subframe down and remove the oil pan.

Item 5: Oil Pan Gasket Removal Note

1. Discard the oil pan gasket.

Items 9 and 10: Oil Pump and Bolts Removal Note

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.

Items 9 and 10: Oil Pump and Bolts Installation Note

1. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207552-S16094195452005113000000) in this section.

Items 3, 4, and 5: Oil Pan Fasteners, Oil Pan, and Oil Pan Gasket Installation Note

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

1. Apply a 10 mm (0.40 in) dot of silicone gasket and sealant to the oil pan gasket in the indicated positions.
2. Gently pry the subframe down and install the oil pan.
3. Position the oil pan and install the studs and bolts. Tighten the bolts in the sequence shown. (Scheme 193)
4. Install the RH subframe bolts.
5. Install the LH subframe bolts.
6. Install the LH and RH engine mount nuts.
7. Install the RH lower control arm through-bolt.
8. Install the LH lower control arm through-bolt.
9. Install the eight bolts and the two front I-braces.

Scheme 168

MATERIAL SPECIFICATION CHART

Scheme 169

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R55S»(ref-207557) .
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, carry out only the listed steps. COMPONENT STEPS SPECIFICATION CHART Component Steps Flexplate 1-2 Crankshaft rear seal 1-4
3. To install, reverse the removal procedure.

Item 4: Crankshaft Rear Seal Removal Note

Scheme 170

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

Item 4: Crankshaft Rear Seal Installation Note

Scheme 171

1. Lubricate the outer lips and the inner seal on the crankshaft rear seal with clean engine oil.
2. Using the special tools, install the crankshaft rear oil seal.

Scheme 172

1. With the vehicle in neutral, position it on a hoist.
2. Remove the intake manifold tuning valves. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
3. Remove the fresh air inlet duct housing. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Item 3: RH Engine Mount Removal Note

1. Raise the engine and remove the engine mount.

Scheme 173

1. With the vehicle in neutral, position it on a hoist.
2. Remove the intake manifold tuning valves. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
3. Remove the fresh air inlet duct housing. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) . .
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Item 2: Intermediate Shaft Pinch Bolt Removal Note

1. Disconnect the steering coupling.

Item 9: Center Crossmember Bolts Removal Note

1. Loosen the center crossmember bolts.

Item 10: LH Engine Mount Removal Note

1. Raise the engine and lower the center crossmember to remove the LH engine mount.

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

Scheme 187

Scheme 188

Scheme 189

1. With the vehicle in NEUTRAL, position on a hoist.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM»(ref-207559).
3. Disconnect the battery ground cable.
4. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555).
5. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
6. Discharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561).
7. Remove the clean air inlet duct. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561).
8. Remove the three-way catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207558).
9. Remove the drive shaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-207547).
10. Remove the components in the order indicated in the following illustration and table. (Scheme 207)
11. Remove the components in the order indicated in the following illustration and table. (Scheme 208)
12. Remove the components in the order indicated in the following illustration and table. (Scheme 209)
13. Remove the components in the order indicated in the following illustration and table. (Scheme 210)
14. Remove the components in the order indicated in the following illustration and table. (Scheme 211)
15. Remove the components in the order indicated in the following illustration and table. (Scheme 212)
16. Remove the components in the order indicated in the following illustration and table. (Scheme 213)
17. Remove the components in the order indicated in the following illustration and table. (Scheme 214)
18. Remove the components in the order indicated in the following illustration and table. (Scheme 215)
19. Remove the components in the order indicated in the following illustration and table. (Scheme 216)
20. Remove the components in the order indicated in the following illustration and table. (Scheme 217)
21. Remove the components in the order indicated in the following illustration and table. (Scheme 218)
22. Remove the components in the order indicated in the following illustration and table. (Scheme 219)
23. Remove the components in the order indicated in the following illustration and table. (Scheme 220)
24. Remove the components in the order indicated in the following illustration and table. (Scheme 221)

Item 2: Spring Lock Coupling Removal Note

Scheme 190

Scheme 191

Scheme 192

Scheme 193

1. Remove the clip.
2. Install the special tool.
3. Close the special tool and push it into the open side of the cage.
4. Separate the fitting and remove the special tool.

Item 14: Heater Hoses Removal Note

1. Disconnect the three quick disconnect couplings from the coolant control valve hose at the heater tube assembly. For additional information, refer to Heater Hose Coupling in «CLIMATE CONTROL SYSTEM»(ref-207561) .

Item 15: Water Valve Electrical Connector Removal Note

Scheme 194

1. Disconnect the water valve electrical connector, unclip the harness from the radiator support and position the harness aside.

Item 32: A/C Low Pressure Hose Removal Note

Scheme 195

1. Disconnect the low pressure A/C hose.

Item 37: Vapor Tube Removal Note

1. Remove the vapor tube from the vapor management valve (VMV).

Item 51: Torque Converter Nuts Removal Note

1. Make sure to mark the torque converter-to-flywheel location.

Item 54: Shift Cable Removal Note

Scheme 196

1. Disconnect the shift cable from the shifter.

Item 55: Shift Cable Removal Note

Scheme 197

1. Unclip the shift cable from the bracket.

Item 56: Power Steering Rack Electrical Connector Removal Note

Scheme 198

1. Disconnect the rack and pinion steering unit electrical connectors and remove the tie-strap.

Item 60: Steering Shaft Removal Note

1. Disconnect the intermediate shaft from the steering gear.

Item 61: Anti-lock Brake Sensor Electrical Connector Removal Note

Scheme 199

Scheme 200

1. Position aside the inner splash shield. Remove the pin-type retainers. Position aside the inner splash shield.
2. Disconnect the wheel speed sensor electrical connector.

Item 62: Anti-lock Brake Sensor Harness Removal Note

Scheme 201

1. Unclip the anti-lock brake harness from the brake hose.

Item 64: Brake Caliper Removal Note

1. Position and secure the brake caliper aside.

Item 66: Upper Ball Joint Nut Removal Note

1. Remove the nut and separate the ball joint from the spindle.

Item 68: Anti-lock Brake Sensor Electrical Connector Removal Note

Scheme 202

Scheme 203

1. Position aside the inner splash shield. Remove the pin-type retainers. Position aside the inner splash shield.
2. Disconnect the wheel speed sensor electrical connector.

Item 69: Anti-lock Brake Sensor Harness Removal Note

Scheme 204

1. Unclip the anti-lock brake harness from the brake hose.

Item 71: Brake Caliper Removal Note

1. Position and secure the brake caliper aside.

Item 73: Upper Ball Joint Nut Removal Note

1. Remove the nut and separate the ball joint from the spindle.

Item 75: Engine and Transmission Removal Note

Scheme 205

Scheme 206

1. Remove the lower air deflector pin-type retainers and remove the air dam.
2. Support the rear of the vehicle with suitable safety stands.
3. Drain the engine oil. Tighten the drain plug.
4. Install the special tools.

Item 81: Front Crossmember Bolts Removal Note

Scheme 207

Scheme 208

1. Carefully lower the engine, transmission, front and center crossmembers, and the cooling system from the vehicle.
2. Install the special tool to the engine.
3. Install the special tool to the engine.

Item 83: Reservoir-to-Pump Supply Removal Note

Scheme 209

1. Drain the power steering pump into a suitable container and disconnect the return hose at the power steering pump.

Item 88: Power Steering Pump Removal Note

Scheme 210

1. Rotate the tensioner counterclockwise and remove the drive belt.

Item 112: Transmission Mounting Bolts Removal Note

Scheme 211

Scheme 212

Scheme 213

1. Remove the transmission from the engine and subframe assembly.
2. Remove the LH engine mount nut.
3. Remove the RH engine mount nut.
4. Using the special tool and an engine crane, remove the engine from the subframe assembly.

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Remove the components in the order indicated in the following illustration and table. (Scheme 249)
2. Remove the components in the order indicated in the following illustration and table. (Scheme 250)
3. Remove the components in the order indicated in the following illustration and table. (Scheme 251)
4. Remove the components in the order indicated in the following illustration and table. (Scheme 252)
5. Remove the components in the order indicated in the following illustration and table. (Scheme 253)
6. Remove the components in the order indicated in the following illustration and table. (Scheme 254)
7. Remove the components in the order indicated in the following illustration and table. (Scheme 255)
8. Remove the components in the order indicated in the following illustration and table. (Scheme 256)
9. Remove the components in the order indicated in the following illustration and table. (Scheme 257)
10. Remove the components in the order indicated in the following illustration and table. (Scheme 258)
11. Remove the components in the order indicated in the following illustration and table. (Scheme 259)
12. Remove the components in the order indicated in the following illustration and table. (Scheme 260)
13. Remove the components in the order indicated in the following illustration and table. (Scheme 261)
14. Remove the components in the order indicated in the following illustration and table. (Scheme 262)
15. Remove the components in the order indicated in the following illustration and table. (Scheme 263)
16. Remove the components in the order indicated in the following illustration and table. (Scheme 264)
17. Remove the components in the order indicated in the following illustration and table. (Scheme 265)
18. Remove the components in the order indicated in the following illustration and table. (Scheme 266)
19. Remove the components in the order indicated in the following illustration and table. (Scheme 267)
20. Remove the components in the order indicated in the following illustration and table. (Scheme 268)
21. Remove the components in the order indicated in the following illustration and table. (Scheme 269)

Item 3: Spacer Plate Disassembly Note

Scheme 236

Scheme 237

1. Unclip the LH and RH wiring harness retainers.
2. Remove the rear separator plate assembly.

Item 4: Crankshaft Rear Seal Disassembly Note

Scheme 238

1. Using the special tools, remove the crankshaft rear seal.
2. Mount the engine on an engine stand.
3. Remove the lifting equipment.

Item 23: Emissions Vacuum Hose Disassembly Note

Scheme 239

Scheme 240

1. Disconnect the fuel pressure sensor jumper from the main vacuum harness.
2. Disconnect the positive crankcase ventilation (PCV) tube at the rear of the upper intake manifold.

Item 25: Engine Wiring Harness Disassembly Note

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

1. Disconnect the throttle body electrical connectors.
2. Disconnect the intake manifold tuning (IMT) valve electrical connectors.
3. Disconnect the fuel injector wiring harness connector.
4. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
5. Disconnect the LH and RH camshaft position (CMP) sensor electrical connectors.
6. Disconnect the crankshaft position (CKP) sensor electrical connector.
7. Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
8. Disconnect the A/C electrical connector.
9. Detach the three wiring harness retainers from the block.
10. Detach the three wiring harness retainers.
11. Remove the nut and wiring harness from the stud.
12. Detach the two wiring harness retainers from the block. Disconnect the generator electrical connector.
13. Disconnect the wiring harness retainers.
14. Unclip the wiring harness retainer.
15. Remove the bolts and the radio ignition interference capacitors.
16. Unclip and disconnect the knock sensor (KS) electrical connector.
17. Remove the four nuts and the wiring harness.
18. Remove the nut and the bracket.
19. Remove the nut and the ground strap.

Item 48: LH Exhaust Manifold Disassembly Note

1. Discard the exhaust manifold gasket.

Items 49-51: Crankshaft Pulley, Bolt, and Washer Disassembly Note

Scheme 259

1. Using the special tool to hold the crankshaft pulley, remove and discard the bolt and washer.
2. Using the special tool, remove the crankshaft pulley.

Item 52: Crankshaft Front Seal Disassembly Note

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

Item 72: RH Exhaust Manifold Disassembly Note

Scheme 260

1. Discard the exhaust manifold gasket.
2. Remove the bolts and the RH engine mount bracket.

Items 84 and 85: LH Valve Cover and Valve Cover Gaskets Disassembly Note

Scheme 261

1. Remove the studs and bolts and remove the LH valve cover and gaskets. Discard the gaskets.

Items 88 and 89: RH Valve Cover and Valve Cover Gaskets Disassembly Note

Scheme 262

1. Remove the studs and bolts and remove the RH valve cover and gaskets. Discard the gaskets.

Item 92: Oil Pan Disassembly Note

Scheme 263

Scheme 264

1. Remove the bolts and the oil pick-up tube. Inspect the O-ring seal for damage.
2. Remove the nuts and the oil pan baffle.

Items 94 and 95: Engine Front Cover and Front Cover Gaskets Disassembly Note

Scheme 265

1. Remove the bolts, the engine front cover and the gasket. Discard the gasket.

Items 96-109: Timing Drive Components Disassembly Note

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

1. Remove the ignition pulse wheel.
2. Install the crankshaft damper bolt and washer.
3. Rotate the crankshaft clockwise to position the crankshaft keyway to the nine o'clock position.
4. Rotate the crankshaft clockwise to position the crankshaft keyway to the three o'clock position.
5. Verify that the front two intake camshaft lobes are pointing up.
6. Compress the timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
7. Remove the bolts and the RH timing chain tensioner.
8. Remove the RH timing chain tensioner arm.
9. Remove the RH timing chain.
10. Remove the bolts and the RH variable camshaft timing (VCT) solenoid housing assembly.
11. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the eleven o'clock position.
12. Compress the timing chain tensioner. Release the racheting pawl. Compress the timing chain tensioner and install a stiff wire or paper clip.
13. Remove the bolts and the LH timing chain tensioner.
14. Remove the LH timing chain tensioner arm.
15. Remove the LH timing chain.
16. Remove the LH VCT solenoid housing assembly.
17. Remove the crankshaft sprockets.

Items 110-114: RH Variable Camshaft Timing (VCT) Actuator, RH Exhaust Camshaft Sprocket and Bolts Disassembly Note

Scheme 281

Scheme 282

1. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH VCT actuator. Discard the bolt.
2. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH exhaust camshaft sprocket. Discard the bolt.

Items 115-121: LH Variable Camshaft Timing (VCT) Actuator, LH Exhaust Camshaft Sprocket and Bolts, and Timing Chain Crankshaft Sprockets Disassembly Note

Scheme 283

Scheme 284

1. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH VCT actuator. Discard the bolt.
2. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH exhaust camshaft sprocket. Discard the bolt.

Items 122 and 125: RH and LH Cylinder Head Bolts Disassembly Note

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

1. Remove the bolts.
2. Using a soft-faced mallet, gently loosen and remove the camshaft journal thrust caps.
3. Remove the remaining camshaft journal cap bolts.
4. Using a soft-faced mallet, gently loosen and remove the remaining camshaft journal caps.
5. Carefully lift out the camshafts.
6. Remove the bolts and the coolant outlet pipe. Discard the O-ring seal.
7. Remove and discard the cylinder head bolts.
8. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.
9. Remove the four oil pump bolts in the sequence shown. (Scheme 330) Remove the oil pump.

Item 128: Engine Assembly Disassembly Note

Scheme 290

Scheme 291

1. Remove the bolts and the inlet tube.
2. Remove the bolt and the top-mounted knock sensor (KS).

Scheme 292

MATERIAL SPECIFICATION CHART

Scheme 293

1. Disassemble the components in the order indicated in the following illustration and table.
2. To assemble, reverse the disassembly procedure.
3. Repeat the procedure until all of the valves are removed.

Items 1, 2, 8, and 9: Tappet Shim and Tappet Disassembly Note

1. Remove the tappet and shim.

Items 3 and 10: Intake and Exhaust Valve Spring Retainer Keys Disassembly Note

Scheme 294

1. Using the special tool, compress the valve spring and remove the retainer keys.

Items 7 and 14: Intake and Exhaust Valves Disassembly Note

1. For component tests of the valve, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) for basic mechanical concerns.
2. Lubricate the valve stem and the valve stem seal with clean engine oil prior to installation.

Item 15: Cylinder Head Disassembly Note

1. For component tests of the cylinder head, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) for basic mechanical concerns.

Scheme 295

MATERIAL SPECIFICATION CHART

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

1. Install the components in the order indicated in the following illustration and table. (Scheme 337)
2. Install the components in the order indicated in the following illustration and table. (Scheme 338)
3. Install the components in the order indicated in the following illustration and table. (Scheme 339)
4. Install the components in the order indicated in the following illustration and table. (Scheme 340)
5. Install the components in the order indicated in the following illustration and table. (Scheme 341)
6. Install the components in the order indicated in the following illustration and table. (Scheme 342)
7. Install the components in the order indicated in the following illustration and table. (Scheme 343)
8. Install the components in the order indicated in the following illustration and table. (Scheme 344)
9. Install the components in the order indicated in the following illustration and table. (Scheme 345)
10. Install the components in the order indicated in the following illustration and table. (Scheme 346)
11. Install the components in the order indicated in the following illustration and table. (Scheme 347)
12. Install the components in the order indicated in the following illustration and table. (Scheme 348)
13. Install the components in the order indicated in the following illustration and table. (Scheme 349)
14. Install the components in the order indicated in the following illustration and table. (Scheme 350)
15. Install the components in the order indicated in the following illustration and table. (Scheme 351)
16. Install the components in the order indicated in the following illustration and table. (Scheme 352)
17. Install the components in the order indicated in the following illustration and table. (Scheme 353)
18. Install the components in the order indicated in the following illustration and table. (Scheme 354)
19. Install the components in the order indicated in the following illustration and table. (Scheme 355)
20. Install the components in the order indicated in the following illustration and table. (Scheme 356)
21. Install the components in the order indicated in the following illustration and table. (Scheme 357)

Item 1: Engine Assembly Note

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

1. Rotate the crankshaft to position the keyway at the nine o'clock position.
2. Position the oil pump and install the bolts.
3. Position the oil pan baffle and install the nuts. Tighten in two stages: Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten an additional 45 degrees.
4. Position the oil pump screen cover and tube and install the bolts. Use a new O-ring seal, if necessary.
5. Position the top-mounted knock sensor (KS) and install the bolt.
6. Using a new O-ring seal, position the coolant inlet tube and install the bolts.

Items 2-7: LH and RH Cylinder Head, Gaskets and Bolts Assembly Note

Scheme 322

Scheme 323

1. Using a new cylinder head gasket, position the cylinder head, and install new bolts. Tighten the bolts in six stages: Stage 1: Tighten to 30 N.m (22 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Back out a minimum of one full turn (360 degrees). Stage 4: Tighten to 30 N.m (22 lb-ft). Stage 5: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.
2. Install the LH and RH spark plugs.
3. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
4. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps, and loosely install the bolts.
5. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the caps, and loosely install the bolts.
6. Tighten the bolts in the sequence shown. (Scheme 369)
7. Lubricate the tappet shims and camshaft lobes with clean engine oil.
8. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.
9. Install the coolant outlet pipe, a new O-ring seal and the 2 bolts. Tighten to 25 N.m (18 lb-ft).

Items 8-19: Variable Camshaft Timing (VCT) Actuators, Exhaust Camshaft Sprockets, Bolts, Washers and Crankshaft Sprockets Assembly Note

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

1. With the two keyways facing forward, install the crankshaft sprockets.
2. Install the LH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
3. Install the LH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
4. Install the RH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Install the RH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages. Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.

Items 20-33: Timing Drive Components Assembly Note

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

1. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the exhaust camshaft timing mark. Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark. Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.
2. Verify that the crankshaft keyway is in the eleven o'clock position.
3. Rotate the LH and RH intake and exhaust camshafts to locate them in their neutral positions.
4. Install the LH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
5. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.
6. Install the LH timing chain tensioner arm.
7. Install the LH timing chain tensioner and bolts.
8. Remove the wire or paper clip from the tensioner.
9. Rotate the crankshaft clockwise and position the keyway at the three o'clock position for RH timing chain installation.
10. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing index marks on the camshaft and crankshaft sprockets.
11. Install the RH VCT solenoid housing assembly and hand-tighten the bolts. Tighten in the sequence shown to 25 N.m (18 lb-ft).
12. Install the RH timing chain, aligning the copper (or marked) links with the marks on the camshaft and crankshaft sprockets.
13. Install the RH timing chain tensioner arm.
14. Install the RH timing chain tensioner and bolts.
15. Remove the wire or paper clip from the RH timing chain tensioner.
16. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
17. Verify that the timing component alignment is correct. There should be LH chain links between the exhaust and intake camshaft timing marks. There should be 23 chain links between the camshaft and crankshaft timing marks. There should be 28 chain links between the camshaft and crankshaft timing marks.
18. Remove the crankshaft damper bolt and washer.
19. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.

Items 20 and 27: VCT System Oil Filters Assembly Note

Scheme 343

1. Remove the bolt and the variable camshaft timing (VCT) solenoid.
2. Remove the VCT system filter cap and replace the VCT system filter.
3. Repeat the previous steps for the RH VCT system filter.

Items 34 and 35: Engine Front Cover and Front Cover Gaskets Assembly Note

Scheme 344

1. Clean the engine front cover to cylinder block and cylinder head sealing surfaces, using a clean shop towel and metal surface cleaner to remove all residue.
2. Install new front cover seals into the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealant to the areas shown.
4. Install the engine front cover and the bolts. Tighten the bolts in the sequence shown.

Items 36-39: Oil Pan Gasket, Oil Pan, Oil Pan Stud and Bolts Assembly Note

Scheme 345

1. Rotate the engine upside down on the engine stand.
2. Clean the oil pan-to-cylinder block sealing surfaces on the oil pan and cylinder block with a clean shop towel and metal surface cleaner to remove all residue.
3. Apply a 10 mm (0.4 in) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the two locations shown.
4. Install the oil pan. Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.
5. Tighten the oil pan bolts in the sequence shown. (Scheme 402)

Items 40 and 41: RH Valve Cover and Gaskets Assembly Note

Scheme 346

1. Install a new gasket in the RH valve cover.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the RH valve cover and install the bolts in the sequence shown.

Items 44 and 45: LH Valve Cover and Gaskets Assembly Note

Scheme 347

1. Install a new gasket in the LH valve cover.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealer to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the LH valve cover and install the bolts in the sequence shown. (Scheme 406)

Items 47-49: Lower Intake Manifold Assembly, Gaskets and Bolts Assembly Note

Scheme 348

Scheme 349

1. Inspect the lower intake manifold gaskets. Install new gaskets if necessary.
2. Position the lower intake manifold assembly and install the bolts in the sequence shown.

Items 57 and 58: RH Exhaust Manifold and Nuts Assembly Note

Scheme 350

Scheme 351

1. Position the RH engine mount bracket and install the bolts.
2. Using a new gasket, position the RH exhaust manifold and install the nuts.

Items 68: Oil Filter Assembly Note

1. Using an oil filter strap wrench, install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Item 77: Crankshaft Front Oil Seal Assembly Note

Scheme 352

1. Using the special tool, install the crankshaft front oil seal.

Items 78-80: Crankshaft Pulley, Bolt, and Washer Assembly Note

Scheme 353

Scheme 354

1. Apply a dot of silicone gasket and sealant to the crankshaft damper keyway slot.
2. Using the special tool, install the crankshaft damper.
3. Using the special tool, install the washer and a new bolt. (Scheme 414) Tighten the bolt in four stages: Stage 1: Tighten to 120 N.m (89 lb-ft). Stage 2: Back out a minimum of one full turn (360 degrees). Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

Items 81 and 82: LH Exhaust Manifold and Nuts Assembly Note

Scheme 355

Scheme 356

1. Position the LH engine mount bracket and install the bolts.
2. Using a new gasket, position the LH exhaust manifold and install the nuts.

Items 92-99: Upper Intake Manifold, Gaskets and Bolts, and Fuel Regulator Shield and Bolts Assembly Note

Scheme 357

Scheme 358

1. Position the upper intake manifold and gaskets. Install the bolts finger tight.
2. Position the fuel pressure sensor shield and install the bolts finger tight.
3. Tighten the upper intake bolts in the sequence shown.

Item 104: Engine Wiring Harness Assembly Note

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

1. Position the ground strap and install the nut.
2. Install the bracket and the nut.
3. Position the wiring harness and install the four nuts.
4. Position the two radio ignition interference capacitors and install the bolts.
5. Attach the wiring harness retainer.
6. Clip the two wiring harness retainers into the brackets and connect the generator electrical connector.
7. Position the wiring harness and install the nut.
8. Attach the three wiring harness retainers.
9. Attach the three wiring harness retainers.
10. Connect the A/C electrical connector.
11. Connect the oil pressure switch electrical connector.
12. Connect the two camshaft position (CMP) sensor electrical connectors.
13. Connect the crankshaft position (CKP) sensor electrical connector.
14. Connect the cylinder head temperature (CHT) sensor electrical connector.
15. Connect the fuel injector wiring harness connector.
16. Connect the intake manifold tuning valve electrical connectors.
17. Connect the throttle body electrical connectors.

Item 106: Emissions Vacuum Hose Assembly Note

Scheme 375

1. Connect the fuel pressure sensor jumper to the main vacuum harness.
2. Connect the positive crankcase ventilation (PCV) tube at the rear of the upper intake manifold.

Item 119: EGR System Module Gasket Assembly Note

Scheme 376

1. Install a new EGR system module gasket with the side with the raised circle facing the intake manifold.

Item 125: Crankshaft Rear Oil Seal Assembly Note

Scheme 377

1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.
2. Using the special tools, install the crankshaft rear oil seal.

Items 126-128: Flexplate Bolts, Flexplate, and Spacer Plate Assembly Note

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

1. Install the special tool onto the engine as shown.
2. Install the special tool onto the engine as shown.
3. Using the special tool and an engine crane, transfer the engine from the stand to the floor or a bench.
4. Install the spacer plate assembly.
5. Attach both the wiring harness retainers, one on each side of the engine.
6. Install the flywheel and the bolts.

Scheme 383

MATERIAL SPECIFICATION CHART

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

1. Install the components in the order indicated in the following illustration and table. see scheme 411
2. Install the components in the order indicated in the following illustration and table. see scheme 412
3. Install the components in the order indicated in the following illustration and table. see scheme 413
4. Install the components in the order indicated in the following illustration and table. see scheme 414
5. Install the components in the order indicated in the following illustration and table. see scheme 415
6. Install the components in the order indicated in the following illustration and table. see scheme 416
7. Install the components in the order indicated in the following illustration and table. see scheme 417
8. Install the components in the order indicated in the following illustration and table. see scheme 418
9. Illustration 9 of 15. Install the components in the order indicated in the following illustration and table.
10. Install the components in the order indicated in the following illustration and table. see scheme 420
11. Install the components in the order indicated in the following illustration and table. see scheme 421
12. Install the components in the order indicated in the following illustration and table. see scheme 422
13. Install the components in the order indicated in the following illustration and table. see scheme 423
14. Install the components in the order indicated in the following illustration and table. see scheme 424
15. Install the components in the order indicated in the following illustration and table. see scheme 425
16. Install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-207547).
17. Install the three-way catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207558).
18. Fill the engine with clean oil
19. Install the clean air inlet duct. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561).
20. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555).
21. Connect the battery ground cable.
22. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
23. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-207550).
24. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561).

Item 1: Transmission Mounting Bolts Installation Note

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

1. Install the special tool to the engine as shown.
2. Install the special tool to the engine as shown.
3. Using an engine crane, transfer the engine to the subframe.
4. Install the LH engine mount nut.
5. Install the RH engine mount nut.
6. Install the transmission to the engine and install the bolts.
7. Remove the special tool.
8. Remove the special tool.

Item 23: O-Ring Installation Note

Scheme 407

1. Using the special tool, install a new Teflon® seal on the pressure line fitting.

Item 26: Power Steering Pump Installation Note

Scheme 408

1. Rotate the tensioner counterclockwise and install the drive belt on the pulley.

Items 32-38: Subframe and Bolts Installation Note

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

1. Position and carefully raise the entire engine, transmission, cooling and subframe assembly into the vehicle.
2. Install the crossmember bolts.
3. Install the RH subframe bolts.
4. Install the LH subframe bolts.
5. Install the transmission support bracket.
6. Remove the powertrain lift and transmission support bracket.
7. Remove the safety stands from the rear of the vehicle.
8. Install the air dam and install the lower air deflector pin-type retainers.

Items 39-52: Front Suspension and Brake Caliper Installation Note

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

1. Install the lower strut mount bolts.
2. Install the upper ball joint nut.
3. Connect the stabilizer link lower mounts and install the nuts.
4. Install the front brake calipers.
5. Connect the anti-lock brake sensor harness to the brake hose clips.
6. Connect the anti-lock brake sensor electrical connector.
7. Install the inner splash shield. Position the inner splash shield back. Install the pin-type retainers.

Item 53: Steering Shaft Installation Note

1. Connect the intermediate shaft to the steering gear and install the pinch bolt.

Item 57: Steering Rack Electrical Connectors Installation Note

Scheme 422

1. Connect the power steering rack electrical connectors.

Item 58: Shift Cable Installation Note

Scheme 423

1. Reclip the shift cable to the bracket.

Item 59: Shift Cable Installation Note

Scheme 424

1. Connect the shift cable to the shifter.

Items 63 and 64: Torque Converter Nuts and Access Cover Installation Note

Scheme 425

1. Install the nuts.
2. Install the access cover.

Item 73: Vapor Management Valve (VMV) Vapor Tube Installation Note

Scheme 426

1. Connect the VMV. Vacuum hose. Canister purge valve.

Item 81: Low Pressure Hose Installation Note

Scheme 427

1. Connect the A/C low pressure hose and install the clip.

Item 98: Coolant Valve Electrical Connector Installation Note

1. Clip the harness to the radiator support and connect the coolant valve electrical connector.

Item 99: Heater Hoses Installation Note

1. Connect the three quick-disconnect couplings from the coolant control valve hoses to the heater tube assembly. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .