Engine - 3.9L: Other Lincoln LS I рестайлинг

Engine Code Information

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

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

Exhaust Emission Control System

Refer to the EMISSION APPLICATIONS .

Induction System

The air/fuel mixture needed for burning in the cylinders is provided by the multiport fuel injection (MFI) system. Refer to INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L for additional information.

Fuel is

1. Supplied from the fuel tank by the fuel pump.
2. Regulated by the fuel pressure sensor.
3. Delivered to the injector supply manifold.

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

Crankshaft

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

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

Camshafts

The camshafts

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

Valve Train

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

1. Provide lash adjustment through a shim selected by thickness.
2. Ride on the camshaft lobes.

Crankcase Ventilation System

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

Oil Pump

The rotary spur oil pump develops the oil pressure.

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

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

Engine Cooling System

The engine is liquid-cooled

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

Drive Belt System

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

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

Scheme 432

The accessory drive

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

Engine Emission Control

The engine emission control consists of the

1. Exhaust gas recirculation (EGR) system.

Scheme 433

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 .

Scheme 434

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 EGR system module to exhaust manifold tube

1. Connects the exhaust manifold to the EGR valve.

The EGR system module transducer

1. Monitors the EGR system module flow rate through the EGR to exhaust manifold tube.
2. 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.

Refer to ENGINE SYSTEM-GENERAL INFORMATION .

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. Refer to the illustrations under «DESCRIPTION AND OPERATION»(ref-207553-S33472535842005113000000) 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 a 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 the EMISSION APPLICATIONS .

Valve Clearance Check

1. Remove the valve covers. For additional information, refer to «VALVE COVER LH»(ref-207553-S41300758332005113000000) or «VALVE COVER RH»(ref-207553-S01213765582005113000000) 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-207553-S28731278102005113000000) in this section.
5. To assemble, reverse the inspection procedure.

Scheme 435

Scheme 436

Scheme 437

1. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) 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-207553-S28177130382005113000000) 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-207553-S28177130382005113000000) in this section.
8. Measure the new valve clearances.
9. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) in this section.

Scheme 438

Scheme 439

1. Remove the front lower splash shield.
2. To remove individual components, carry out only the listed steps. ACCESSORY DRIVE BELT, TENSIONER AND PULLEY COMPONENTS STEPS Component Steps Accessory drive belt 1 Accessory drive belt idler pulley 1-3 Accessory drive belt tensioner 1, 4-5
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Scheme 440

1. Remove the engine appearance cover.
2. To remove individual components, carry out only the individual steps. EXHAUST GAS RECIRCULATION (EGR) VALVE COMPONENT STEPS Component Steps Exhaust gas recirculation (EGR) system module 1-4 Exhaust manifold tube-to-EGR system module 1-8
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Item 2: Exhaust Manifold Tube Removal Note

Scheme 441

1. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.

Item 3: EGR System Module Bolt Removal Note

Scheme 442

1. Remove the vacuum harness.

Item 6: Intake Manifold Removal Note

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-207553-S26687117902005113000000) in this section.

Item 6: Intake Manifold Installation Note

1. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-207553-S26687117902005113000000) in this section.

Item 5: EGR System Module Gasket Installation Note

Scheme 443

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

Item 2: Exhaust Manifold Tube Installation Note

Scheme 444

1. Connect the EGR system module-to-exhaust manifold tube to the EGR system module.

Item 3: EGR System Module Bolt Installation Note

Scheme 445

1. Install the vacuum harness.

Material

MATERIAL SPECIFICATION

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
4. Remove the cowl vent screen. For additional information, refer to «INTERIOR TRIM»(ref-207570).
5. Remove the engine compartment brace.
6. Disconnect the fuel line. For additional information, refer to «FUEL SYSTEM»(ref-207559).
7. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 450)
8. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 451)
9. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 452)
10. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 453)
11. To install, reverse the removal procedure.

Items 11 and 13: Engine Appearance Cover Support Bracket Removal Note

1. Disconnect the engine wiring harness retainers from the engine appearance cover support bracket.

Items 14, 15, and 16: Intake Manifold Removal Note

Scheme 451

Scheme 452

1. Disconnect the fuel injector and RFI suppressor electrical connectors
2. Remove the nuts and the engine wiring harness retainer and position aside.
3. Remove the nut and the RFI suppressor.
4. Disconnect the throttle body heater hoses.
5. Remove the bolts and studs in the sequence shown.
6. Remove the intake manifold.
7. Clean the sealing surfaces.

Items 14, 15, and 16: Intake Manifold Installation Note

Scheme 453

Scheme 454

1. Install new intake manifold gaskets.
2. Install the intake manifold and tighten the bolts in the sequence shown.
3. Connect the throttle body heater hoses.
4. Install the RFI suppressor and the nut.
5. Install the engine wiring harness retainer and the nuts.
6. Connect the fuel injector and RFI suppressor electrical connectors

Item 7 and 9: Engine Appearance Cover Support Bracket Installation Note

1. Connect the engine wiring harness retainers to the engine appearance cover support bracket.

Scheme 455

MATERIAL SPECIFICATION

Scheme 456

Scheme 457

Scheme 458

1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Remove the LH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-207553-S36345318972005113000000) in this section.
5. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM»(ref-207559).
6. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 468)
7. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 469)
8. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 470)
9. To install, reverse the removal procedure.

Item 2: Spring Lock Coupling Removal Note

Scheme 459

Scheme 460

Scheme 461

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

Item 11: LH Valve Cover Removal Note

Scheme 462

Scheme 463

Scheme 464

Scheme 465

1. Disconnect the crankcase ventilation tube.
2. Disconnect the evaporative emission (EVAP) canister purge valve hose.
3. Remove the fuel hose bracket bolt from the LH shock tower.
4. Loosen the bolts and position the power steering pump reservoir aside.
5. Remove the LH valve cover. Loosen the bolts in the sequence shown.
6. Clean the sealing surfaces.
7. Install new gaskets.

Item 11: LH Valve Cover Installation Note

Scheme 466

Scheme 467

Scheme 468

Scheme 469

1. Apply two beads of silicone gasket and sealant as shown. (Scheme 480)
2. Install the LH valve cover. Position the valve cover and tighten the bolts in the sequence shown.
3. Install the power steering pump reservoir.
4. Install the fuel hose bracket bolt.
5. Connect the crankcase ventilation tube.

MATERIAL SPECIFICATION

Scheme 470

Scheme 471

1. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
2. Remove the RH ignition coils. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 485)
4. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 486)
5. To install, reverse the removal procedure.

Item 8: RH Valve Cover removal Note

Scheme 472

Scheme 473

1. Remove the RH valve cover. Loosen the bolts in the sequence shown.
2. Clean the sealing surfaces.
3. Inspect and install new gaskets as necessary.

Item 8: RH Valve Cover Installation Note

Scheme 474

1. Apply two beads of silicone gasket and sealant as shown. (Scheme 490)
2. Install the RH valve cover. Tighten the bolts in the sequence shown. (Scheme 491)

Scheme 475

MATERIAL SPECIFICATION

Scheme 476

1. Remove the cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-207554) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT, TENSIONER AND PULLEY»(ref-207553-S28737290532005113000000) in this section.
3. Remove the oil cooler. For additional information, refer to «OIL COOLER»(ref-207553-S29036104372005113000000) in this section.
4. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. CRANKSHAFT PULLEY AND CRANKSHAFT SEAL COMPONENT STEPS Component Steps Crankshaft pulley 1-2 Front crankshaft seal 1-3
5. To install, reverse the removal procedure.

Items 1-3: Crankshaft Pulley, Bolt and Washer Removal Note

Scheme 477

Scheme 478

1. Remove and discard the bolt.
2. Using the special tool, remove the crankshaft pulley.

Item 4: Front Crankshaft Seal Removal Note

Scheme 479

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

Item 4: Front Crankshaft Seal Installation Note

Scheme 480

1. Using the special tool, install a new front crankshaft seal.

Items 1-3: Crankshaft Pulley, Bolt and Washer Installation Note

Scheme 481

Scheme 482

1. Apply a bead of silicone gasket and sealant to the keyway.
2. Using the special tool, install the crankshaft pulley.
3. Install a new bolt and tighten in four stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Loosen the bolt two complete turns. Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

MATERIAL SPECIFICATION

Scheme 483

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .
2. Drain the engine oil.
3. Remove the LH valve cover. For additional information, refer to «VALVE COVER LH»(ref-207553-S41300758332005113000000) in this section.
4. Remove the RH valve cover. For additional information, refer to «VALVE COVER RH»(ref-207553-S01213765582005113000000) in this section.
5. Remove the engine cooling fan assembly. For additional information, refer to «ENGINE COOLING»(ref-207554) .
6. Remove the crankshaft pulley and crankshaft seal. For additional information, refer to «CRANKSHAFT PULLEY AND CRANKSHAFT SEAL»(ref-207553-S18031230982005113000000) in this section.
7. Remove the A/C compressor. For additional information, refer to «ENGINE COOLING»(ref-207554) .
8. Remove the components in the order indicated in the following illustration and table.
9. To install, reverse the removal procedure.

Items 1, 2 and 3: Engine Front Cover Removal Note

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

1. Disconnect the lower radiator-to-thermostat housing hose.
2. Disconnect the heater hose.
3. Remove the stud bolt.
4. Remove the bolts and position the power steering pump aside.
5. Remove the coolant pump pulley bolts and the pulley.
6. Remove the power steering pump bracket.
7. Disconnect the five wiring harness clips.
8. Remove the engine front cover. Remove the bolts in the sequence shown. (Scheme 509) Remove the engine front cover.
9. Clean the sealing surfaces with metal surface cleaner.

Items 1, 2 and 3: Engine Front Cover Installation Note

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

1. Install new gaskets.
2. Apply silicone gasket and sealant in the eight places shown. (Scheme 512)
3. Install the engine front cover. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. (Scheme 513) Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
4. Connect the five wiring harness clips.
5. Install the power steering pump bracket.
6. Install the coolant pump pulley and bolts and tighten in 2 stages: Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten an additional 45 degrees.
7. Position the power steering pump and install the bolts.
8. Connect the heater hose.
9. Connect the lower radiator hose to the thermostat housing.
10. Install the stud bolt.

Scheme 498

MATERIAL SPECIFICATION

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-207553-S08841931702005113000000) in this section.
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. TIMING DRIVE COMPONENTS STEPS Component Steps Timing gears, chain and tensioners 1-20 Variable camshaft timing (VCT) bush carriers 1-9 VCT units, exhaust camshaft sprockets, secondary timing chains and tensioners, and crankshaft sprocket 1-37
3. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 522)
4. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 523)
5. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 524)
6. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table. (Scheme 525)and (Scheme 526).
7. To install, reverse the removal procedure.

Items 7-20: Timing Drive Components Removal Note

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

1. Remove the crankshaft position (CKP) sensor and the torque converter cover.
2. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
3. Make sure the flats of the camshaft are facing upward. If not, repeat Step 2 .
4. Install the special tool on the RH cylinder head.
5. Remove and discard the RH exhaust camshaft sprocket bolt.
6. Remove and discard the RH VCT unit bolt.
7. Remove the RH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
8. Remove the RH tensioner arm.
9. Remove the RH timing chain guide.
10. Remove the RH primary timing chain.
11. Remove the special tool from the RH cylinder head.
12. Install the special tool on the LH head.
13. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
14. Remove the LH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
15. Remove the LH tensioner arm.
16. Remove the LH timing chain guide.
17. Remove the LH primary timing chain.

Items 21-25, and 27: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Removal Note

Scheme 515

Scheme 516

1. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
2. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 28-32, and 34: LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Removal Note

Scheme 517

Scheme 518

1. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
2. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 28-32, and 34: LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

Scheme 519

Scheme 520

Scheme 521

1. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the LH secondary timing chain tensioner.

Items 21-25, and 27: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

Scheme 522

Scheme 523

Scheme 524

1. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the RH secondary timing chain tensioner.

Items 7-20: Timing Drive Components Installation Note

Scheme 525

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

1. Reset the timing chain tensioners. Hold the lever toward the tensioner piston. Using finger pressure, compress the tensioner until it is completely collapsed. Push the lever down and install a drill rod to lock the piston.
2. Position the LH timing chain and crankshaft gear. Position the timing chain over the LH intake camshaft sprocket. Position the crankshaft gear in the timing chain.
3. Install the LH timing chain guide.
4. Install the LH timing chain tensioner arm.
5. Install the LH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
6. Tighten the LH exhaust camshaft sprocket and VCT unit bolts in two stages: Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
7. Remove the special tool.
8. Install the special tool on the RH cylinder head.
9. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
10. Install the RH timing chain guide.
11. Install the RH timing chain tensioner arm.
12. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
13. Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages: Stage 1: Tighten to 20 N.m (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
14. Remove the special tool.
15. Remove the special tool.
16. Install the CKP sensor and the torque converter cover.

Scheme 537

MATERIAL SPECIFICATION

Scheme 538

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) in this section.
2. Remove the components in the order indicated in the following illustration and table. (Scheme 571)
3. To install, reverse the removal procedure.

Items 1-6: Camshaft Removal Note

Scheme 539

Scheme 540

Scheme 541

1. Remove the special tool.
2. Remove the RH camshaft bearing caps. Remove the bolts. Remove the RH camshaft bearing caps.
3. Remove the RH camshafts.
4. Remove the LH camshaft bearing caps. Remove the bolts. Remove the LH camshaft bearing caps.
5. Remove the LH camshafts.

Items 1-7: Camshaft Installation Note

1. Position the LH camshafts on the camshaft journals.
2. Install the LH camshaft bearing caps. Position the bearing caps. Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. (Scheme 578) Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
3. Install the RH camshafts.
4. Install the RH camshaft bearing caps. Position the bearing caps. Install the bolts. Tighten the bolts in three stages in the sequence shown. (Scheme 580) Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
5. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-207553-S24807556192005113000000) in this section.
6. If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-207553-S28731278102005113000000) in this section.
7. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) in this section.

Scheme 542

Scheme 543

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the three-way catalytic (TWC) converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207558) .
3. Remove the screws and the lower RH splash shield.
4. Remove the fresh air inlet duct. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.

Items 6 and 7: RH Exhaust Manifold Installation Note

Scheme 544

1. Install the exhaust manifold gasket and stud bolt.
2. Install the exhaust manifold. Install the exhaust manifold. Install the exhaust manifold nuts hand tight. Install the exhaust gas recirculation (EGR) system module-to-exhaust manifold tube to the exhaust manifold. Tighten the eight nuts in the sequence shown.

MATERIAL SPECIFICATION

Scheme 545

Scheme 546

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Hold the steering wheel in the straight-ahead position using a suitable holding device.
3. Remove the three-way catalytic (TWC) converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207558) .
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-207553-S36345318972005113000000) in this section.
5. Remove the screws and the sight shield.
6. Remove the components in the order indicated in the following illustration and table.
7. To install, reverse the removal procedure.

Item 6: LH Exhaust Manifold Nut Removal Note

1. Remove the exhaust manifold. Remove the eight nuts. Remove the exhaust manifold and discard the gasket.

Items 6: LH Exhaust Manifold Nut Installation Note

Scheme 547

1. Install the exhaust manifold. Install a new gasket and the exhaust manifold. Tighten the eight nuts in the sequence shown.

MATERIAL SPECIFICATION

Scheme 548

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554) .
3. Drain the engine oil.
4. Remove the lower splash shield.
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.

Item 9: Oil Cooler Installation Note

1. Position the oil cooler and a new gasket and install the bolt. Rotate the cooler clockwise until the locating pin hits the stop.

Items 7 and 8: Oil Filter and Gasket Installation Note

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

MATERIAL SPECIFICATION

Scheme 549

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
3. Drain the engine oil.
4. Remove the lower splash shield.
5. Remove the components in the order indicated in the following illustration and table. (Scheme 591)
6. To install, reverse the removal procedure.

Item 14: Oil Filter Adapter Removal Note

Scheme 550

1. Remove the oil filter adapter assembly. Discard the seal.
2. Clean the sealing surfaces.

Item 14: Oil Filter Adapter Installation Note

1. Install a new seal and the oil filter adapter. Tighten the bolts in two stages. Stage 1: Tighten to 13 N.m (10 lb-ft). Stage 2: Tighten an additional 90 degrees.

Item 9: Oil Cooler Installation Note

1. Position the oil cooler and a new gasket and install the bolt. Rotate the cooler clockwise until the locating pin hits the stop.

Items 7 and 8: Oil Filter and Gasket Installation Note

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

MATERIAL SPECIFICATION

Scheme 551

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

Item 2: Oil Level Indicator Tube Removal Note

Scheme 552

Scheme 553

1. Remove the bolts and position the power steering reservoir aside.
2. Remove the oil level indicator tube and discard the O-ring seal.

Item 3: Oil Level Indicator Tube Installation Note

Scheme 554

1. Install a new O-ring seal and the oil level indicator tube. Lubricate the new O-ring seal and engine mating surface with clean engine oil.
2. Position the power steering reservoir and install the bolts.

MATERIAL SPECIFICATION

Scheme 555

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine oil.
3. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. OIL PAN, OIL PUMP, OIL PUMP SCREEN AND PICKUP TUBE COMPONENT STEPS Component Steps Oil Pan 1-3 Oil Pump Screen and Pickup Tube 1-5 Oil Pump 1-8
4. To install, reverse the removal procedure.

Item 1: Oil Pan Bolts Removal Note

1. Remove the bolts.
2. Remove the bolts and the lateral support bar.

Items 4 and 5: Oil Pump Screen and Pickup Tube Removal Note

1. Remove the bolts and the oil pump screen and pickup tube. Inspect the O-ring seal and install a new one if necessary.

Items 6-8: Oil Pump Removal Note

Scheme 556

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) in this section.
2. Remove the bolts and the oil pump. Discard the gasket.
3. Clean the sealing surfaces.

Items 6-8: Oil Pump Installation Note

Scheme 557

Scheme 558

1. Install a new gasket.
2. Install the oil pump and tighten the bolts in two stages. Stage 1: Tighten to 6 N.m (53 lb-in). Stage 2: Tighten an additional 90 degrees.
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-207553-S36394504692005113000000) in this section.

Items 4 and 5: Oil Pump Screen and Pickup Tube Installation Note

1. Install the oil pump screen and pickup tube.

Items 1-3: Oil Pan Installation Note

1. Install a new oil pan gasket and the oil pan. Tighten the bolts in the sequence shown in two stages: Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 12 N.m (9 lb-ft).
2. Position the lateral support bars and install the bolts.
3. Install the bolts.
4. Fill the crankcase with clean engine oil.

Scheme 559

MATERIAL SPECIFICATION

Scheme 560

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, only carry out the listed steps. FLEXPLATE OR FLYWHEEL AND CRANKSHAFT REAR SEAL COMPONENT STEPS Component Steps Flexplate 1-2 Rear Crankshaft Seal 1-3
3. To install, reverse the removal procedure.

Item 3: Crankshaft Rear Seal Removal Note

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

Item 3: Crankshaft Rear Seal Installation Note

Scheme 561

1. Position the rear oil seal with the protective installer onto the end of the crankshaft.
2. Using the special tool, install a new crankshaft rear oil seal.

Items 1 and 2: Flexplate Installation Note

Scheme 562

1. Install the flexplate with the elongated hole over the crankshaft dowel.
2. Install the flexplate bolts and tighten in two stages in the sequence shown. (Scheme 617) Stage 1: Tighten to 15 N.m (11 lb-ft). Stage 2: Tighten to 110 N.m (81 lb-ft).

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
4. Remove the upper radiator sight shield.
5. Install the special tools and support the engine.
6. Remove the LH and the RH lower splash shield.
7. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps. INDIVIDUAL COMPONENTS REMOVING STEPS Component Steps RH Motor Mount 1-6 LH Motor Mount 7-12
8. To install, reverse the removal procedure.

Item 12: RH Motor Mount Bracket Removal Note

Scheme 568

Scheme 569

1. Remove the nut and disconnect the starter motor ground cable.
2. Remove the nut and disconnect the wiring harness support bracket from the engine mount bracket.

Item 12: RH Motor Mount Bracket Installation Note

Scheme 570

Scheme 571

1. Connect the starter motor ground cable and install the nut.
2. Connect the wiring harness support bracket to the engine mount bracket and install the nut.

Scheme 572

MATERIAL SPECIFICATION

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

1. Remove the engine. For additional information, refer to «ENGINE»(ref-207553-S21493209122005113000000) under REMOVAL in this section.
2. Mount the engine on a suitable engine stand.
3. To remove individual components, carry out only the listed steps. INDIVIDUAL COMPONENTS REMOVING STEPS Component Step RH cylinder head 1-76, 83-133, 142-144 LH cylinder head 1-82, 89-125, 134-141, 145-147
4. Illustration 1 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 628)
5. Illustration 2 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 629)
6. Illustration 3 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 630)
7. Illustration 4 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 631)
8. Illustration 5 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 632)
9. Illustration 6 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 633)
10. Illustration 7 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 634)
11. Illustration 8 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 635)
12. Illustration 9 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 636)
13. Illustration 10 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 637)
14. Illustration 11 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 638)
15. Illustration 12 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 639)
16. Illustration 13 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 640)
17. Illustration 14 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 641)
18. Illustration 15 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 642)
19. Illustration 16 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 643)
20. Illustration 17 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 644)
21. Illustration 18 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 645)
22. Illustration 19 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 646)
23. Illustration 20 of 20. Remove the components in the order indicated in the following illustration and table. (Scheme 647)

Items 1 and 2: Flanged Plug Removal Note

1. Drain the coolant from the engine block.

Item 9: Coolant Pump Pulley Bolts Removal Note

1. Loosen the coolant pump pulley bolts prior to removing the accessory drive bolt.

Item 15: Coolant Pump Pulley Removal Note

1. Remove the coolant pump pulley bolts and the coolant pump pulley.

Items 16-18: Crankshaft Pulley Removal Note

Scheme 590

1. Remove the bolt and washer. Discard the bolt and washer.
2. Using the special tool, remove the crankshaft damper.

Item 19: Crankshaft Front Seal Removal Note

Scheme 591

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

Items 27-30: RH and LH Coil Cover Removal Note

Scheme 592

Scheme 593

1. Remove all silicone sealer and residue from the coil covers.
2. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.

Items 41 and 42: Engine Cover Support Bracket Removal Note

Scheme 594

1. Disconnect the engine wiring harness retainers from the engine cover support bracket.

Item 43: Engine Wiring Harness Removal Note

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

1. Disconnect the engine wiring harness retainers from the RH engine appearance cover support bracket.
2. Disconnect the fuel injector and radio interference capacitor electrical connectors
3. Disconnect the ignition coil electrical connectors.
4. Disconnect the EGR system module electrical connector.
5. Remove the nuts and the engine wiring harness retainer and position aside.
6. Disconnect the variable cam timing (VCT) sensor electrical connector.
7. Disconnect the wiring harness retainers from the LH valve cover.
8. Disconnect the three wiring harness retainers from the RH valve cover.
9. Disconnect the pin-type retainers.
10. Disconnect the generator electrical connector.
11. Remove the wiring harness from the front cover.
12. Remove the wiring harness from the front cover.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
14. Remove the heated oxygen sensor (HO2S) connectors from the brackets.
15. Remove the engine wiring harness from the engine.

Item 52: EGR System Module Removal Note

Scheme 603

1. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.

Items 65-67 Intake Manifold Removal Note

Scheme 604

1. Remove the nut and the radio interference capacitor.
2. Remove the bolts and studs in the sequence shown. (Scheme 669)
3. Remove the intake manifold.
4. Clean the sealing surfaces.

Items 69-71: RH Valve Cover Removal Note

Scheme 605

1. Remove the bolts in the sequence shown and remove the RH valve cover. (Scheme 671)
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

Items 73-75: LH Valve Cover Removal Note

Scheme 606

1. Remove the bolts in the sequence shown and remove the LH valve cover.
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

Item 86: RH Exhaust Manifold Removal Note

1. Remove the EGR tube. Remove the nuts. Remove the EGR tube. Remove and discard the EGR tube gasket.

Items 89 and 90: Engine Front Cover Removal Note

Scheme 607

1. Remove the engine front cover. Remove the bolts in the sequence shown. Remove the engine front cover.
2. Clean the sealing surfaces.

Items 97-115, 112-122, 124: Timing Drive Components Removal Note

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

1. Remove the crankshaft position (CKP) sensor.
2. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
3. Make sure the flats of the camshaft are facing upward. If not, repeat Step 1 .
4. Install the special tool on the RH cylinder head.
5. Remove and discard the exhaust camshaft sprocket bolt.
6. Remove and discard the variable camshaft timing (VCT) unit bolt.
7. Remove the RH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
8. Remove the tensioner arm.
9. Remove the timing chain guide.
10. Remove the RH primary timing chain.
11. Remove the special tool from the RH head.
12. Install the special tool on the LH head.
13. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
14. Remove the LH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
15. Remove the tensioner arm.
16. Remove the timing chain guide.
17. Remove the LH primary timing chain.
18. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
19. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
20. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
21. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
22. Remove the special tool from the LH head.

Items 126-141: RH and LH Camshaft Removal Note

1. Record the camshaft component locations prior to removal.

Items 142-147: RH and LH Cylinder Head Removal Note

1. Remove and discard the bolts.
2. Remove and discard the head bolts in the sequence shown.
3. Remove and discard the head gasket(s).
4. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
5. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. 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).

Scheme 624

Scheme 625

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the air cleaner assembly and outlet pipe. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
4. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-207554) .
5. Discharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .
6. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM»(ref-207559) .
7. Remove the fresh air filter panel. For additional information, refer to air distribution ducts in «CLIMATE CONTROL SYSTEM»(ref-207561) .
8. Remove the front wheels and tires. .
9. Remove the three-way catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207558) .
10. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-207547) .
11. Remove the parts in the order indicated in the following illustrations and tables.

Scheme 626

Scheme 627

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Item 2: Spring lock coupling Removal Note

Scheme 639

Scheme 640

Scheme 641

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

Item 7: Vapor Tube Removal Note

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

Item 8: Power Steering Reservoir Removal Note

Scheme 642

1. Remove the power steering reservoir bolts.

Item 14: Heater Hoses Removal Note

1. Disconnect the three quick disconnect couplings from the coolant control valve hose at the heater tube assembly. Refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .

Item 15: Water Valve Electrical Connector Removal Note

Scheme 643

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 644

1. Disconnect the low pressure A/C hose.

Item 33: Anti-lock Brake Sensor Electrical Connector Removal Note

Scheme 645

Scheme 646

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

Item 34: Anti-lock Brake Sensor Harness Removal Note

Scheme 647

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

Item 36: Brake Caliper Removal Note

1. Position the caliper aside and secure.

Item 38: Upper Ball Joint Nut Removal Note

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

Item 40: Anti-Lock Brake Sensor Electrical Connector Removal Note

Scheme 648

Scheme 649

1. Position the inner splash shield aside. Remove the pin-type retainers. Position the inner splash shield aside.
2. Disconnect the anti-lock brake sensor electrical connector.

Item 41: Anti-lock Brake Sensor Harness Removal Note

Scheme 650

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

Item 43: Brake Caliper Removal Note

1. Position the caliper aside and secure.

Item 45: Upper Ball Joint Nut Removal Note

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

Item 47: Shift Cable Removal Note

Scheme 651

1. Disconnect the shift cable from the shifter.

Item 48: Shift Cable Removal Note

Scheme 652

1. Unclip the shift cable from the bracket.

Item 49: Power Steering Rack Electrical Connector Removal Note

Scheme 653

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

Item 62: Transmission-to-Engine Bolt Removal Note

1. Remove the lower six transmission-to-engine bolts.

Item 64: Torque Converter Nut Removal Note

1. Remove the eight torque converter nuts.

Item 65: Engine and Transmission Removal Note

Scheme 654

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. Install the special tools.

Item 70: Engine and Transmission Assembly Removal Note

1. Carefully lower the entire assembly from the vehicle.

Item 71: Power Steering Return Hose Removal Note

Scheme 655

1. Drain the reservoir and disconnect the return hose at the power steering pump.

Item 72: Engine Block Heater Removal Note

Scheme 656

1. Disconnect the engine block heater electrical connector if equipped.

Item 82: Engine and Transmission Assembly Removal Note

Scheme 657

Scheme 658

1. Install the special tool.
2. Install the special tool.
3. Using the special tool and an engine crane, support the engine and transmission in the front subframe.

Item 90: Engine and Transmission Removal Note

Scheme 659

1. Using the special tool and an engine crane, move the engine and transmission from the subframe to rest on the floor or on a bench.

Item 95 and 96: Engine Wiring Harness Removal Note

1. Remove the nuts and position the harness aside.

Item 97: Engine-to-Transmission Bolt Removal Note

Scheme 660

1. Remove the bolts and separate the engine from the transmission.

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

1. Illustration 1 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 743)
2. Illustration 2 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 744)
3. Illustration 3 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 745)
4. Illustration 4 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 746)
5. Illustration 5 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 747)
6. Illustration 6 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 748)
7. Illustration 7 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 749)
8. Illustration 8 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 750)
9. Illustration 9 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 751)
10. Illustration 10 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 752)
11. Illustration 11 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 753)
12. Illustration 12 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 754)
13. Illustration 13 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 755)
14. Illustration 14 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 756)
15. Illustration 15 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 757)
16. Illustration 16 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 758)
17. Illustration 17 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 759)
18. Illustration 18 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 760)
19. Illustration 19 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 761)
20. Illustration 20 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 762)
21. Illustration 21 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 763)
22. Illustration 22 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 764)
23. Illustration 23 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 765)
24. Illustration 24 of 24. Remove the components in the order indicated in the following illustration and table. (Scheme 766)

Items 1 and 2: Flexplate Disassembly Note

Scheme 686

1. Remove the flexplate. Remove the bolts in the sequence shown. (Scheme 767) Remove the flexplate.

Item 3: Crankshaft Rear Seal Disassembly Note

Scheme 687

1. Using the special tools, remove the rear main seal. Discard the seal.
2. Install the engine on a suitable engine stand.

Items 36 and 38: RH and LH Coil Cover Disassembly Note

Scheme 688

Scheme 689

1. Remove all silicone sealer and residue from the coil covers.
2. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.

Item 39: Engine Wiring Harness Disassembly Note

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

1. Disconnect the engine wiring harness retainers from the engine appearance cover support bracket.
2. Disconnect the fuel injector and radio interference capacitor electrical connectors
3. Remove the nuts and the engine wiring harness retainer and position aside.
4. Disconnect the variable cam timing (VCT) sensor electrical connector.
5. Disconnect the wiring harness retainers from the LH valve cover.
6. Disconnect the three wiring harness retainers from the RH valve cover.
7. Disconnect the power steering pressure (PSP) switch.
8. Disconnect the A/C electrical connector and the retaining clip.
9. Disconnect the two pin-type retainers.
10. Remove the wiring harness from the front cover.
11. Remove the wiring harness from the front cover.
12. Disconnect the crankshaft position (CKP) sensor electrical connector.
13. Remove the heated oxygen sensor (HO2S) connectors from the brackets.
14. Remove the engine wiring harness from the engine.

Items 65-67: Crankshaft Pulley Disassembly Note

Scheme 700

Scheme 701

1. Remove the bolt and washer. Discard the bolt and washer.
2. Using the special tool, remove the crankshaft damper.

Item 68: Crankshaft Front Seal Disassembly Note

Scheme 702

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

Item 74: Fuel Charge Manifold Disassembly Note

1. Remove the nut and the radio interference capacitor.

Items 79-81: Intake Manifold Disassembly Note

Scheme 703

1. Disconnect and remove the throttle body heater hoses.
2. Remove the bolts and studs in the sequence shown. (Scheme 789)
3. Remove the intake manifold.
4. Clean the sealing surfaces.

Items 83-85: RH Valve Cover Disassembly Note

Scheme 704

1. Remove the bolts in the sequence shown and remove the RH valve cover.

Items 87-89: LH Valve Cover Disassembly Note

Scheme 705

1. Remove the bolts in the sequence shown and remove the LH valve cover.

Items 105 and 109: Exhaust Manifold Disassembly Note

1. Remove the exhaust manifolds. Remove the sixteen nuts and discard. Remove the exhaust manifolds, stud bolts and discard the gaskets. Remove the exhaust manifolds, stud bolts and discard the gaskets.
2. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) .

Items 112 and 113: Engine Front Cover Disassembly Note

Scheme 706

1. Remove the engine front cover. Remove the bolts in the sequence shown. Remove the engine front cover.
2. Clean the sealing surfaces.

Item 114: Sump Body Assembly Disassembly Note

Scheme 707

1. Remove the oil pump screen and tube, and the seal.
2. Remove the four bolts and the oil pump. Discard the gasket.
3. Remove the bolts in the sequence shown and remove the sump body. (Scheme 797)

Items 121-139, 141-146, 148: Timing Drive Components Disassembly Note

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

1. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
2. Make sure the flats of the camshaft are facing upward. If not, repeat Step 1 .
3. Install the special tool on the RH cylinder head.
4. Remove and discard the exhaust camshaft sprocket bolt.
5. Remove and discard the variable camshaft timing (VCT) unit bolt.
6. Remove the RH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
7. Remove the tensioner arm.
8. Remove the timing chain guide.
9. Remove the RH primary timing chain.
10. Remove the special tool from the RH head.
11. Install the special tool on the LH head.
12. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
13. Remove the LH timing chain tensioner. Push the lever down and install a drill rod to lock the piston. Remove the bolts and the tensioner.
14. Remove the tensioner arm.
15. Remove the timing chain guide.
16. Remove the LH primary timing chain.
17. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
18. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
19. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
20. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 150-165: RH and LH Camshaft Disassembly Note

1. Record the camshaft component locations prior to removal.

Items 166-167 and 169-170: RH and LH Cylinder Head Disassembly Note 1.

Scheme 722

Scheme 723

Scheme 724

1. Remove the LH and RH cylinder head end bolts. Discard the bolts.
2. Remove the bolts from both cylinder heads in the sequence shown. (Scheme 818) Discard the bolts.
3. Remove the cylinder heads. Discard the gaskets.
4. Clean the sealing surfaces.
5. Remove the bolts and the knock sensors.

Scheme 725

MATERIAL SPECIFICATION

Scheme 726

1. Remove the components in the order indicated in the following illustration and table. (Scheme 823)
2. To assemble, reverse the disassembly procedure.

Items 1-10: Retainer Keys, Retainers, Valve Spring, Valve Seals, and Valves Disassembly Note

Scheme 727

Scheme 728

Scheme 729

Scheme 730

1. Using the special tool, remove the valve spring retainer keys.
2. Remove the valve spring assembly. Remove the valve spring retainer. Remove the valve spring.
3. Remove the valve stem seal.
4. Remove the valve. For component tests for the valve, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) . For component tests for the cylinder head, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207551) .
5. Repeat the procedure until all of the valves are removed from the cylinder head.

Items 10-1: Retainer Keys, Retainers, Valve Spring, Valve Seals, and Valves Assembly Note

Scheme 731

1. Install the valve stem seal.
2. Install the valve.
3. Using the special tool, install the valve spring, retainer and retainer keys.
4. Repeat the procedure until all of the valves are installed into the cylinder head.

Scheme 732

MATERIAL SPECIFICATION

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

1. Illustration 1 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 832)
2. Illustration 2 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 833)
3. Illustration 3 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 834)
4. Illustration 4 of 23. Remove the components in the order indicated in the following illustration and table. (Scheme 835)
5. Illustration 5 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 836)
6. Illustration 6 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 837)
7. Illustration 7 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 838)
8. Illustration 8 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 839)
9. Illustration 9 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 840)
10. Illustration 10 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 841)
11. Illustration 11 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 842)
12. Illustration 12 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 843)
13. Illustration 13 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 844)
14. Illustration 14 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 845)
15. Illustration 15 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 846)
16. Illustration 16 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 847)
17. Illustration 17 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 848)
18. Illustration 18 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 849)
19. Illustration 19 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 850)
20. Illustration 20 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 851)
21. Illustration 21 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 852)
22. Illustration 22 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 853)
23. Illustration 23 of 23. Install the components in the order indicated in the following illustration and table. (Scheme 854)

Items 2-7: Cylinder Head Assembly Note

Scheme 756

Scheme 757

Scheme 758

Scheme 759

1. Install the knock sensors.
2. Position the cylinder heads. Install new gaskets.
3. Install and tighten the RH head bolts in four stages in the sequence shown. (Scheme 857) Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
4. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.
5. Install and tighten the LH head bolts in four stages in the sequence shown. (Scheme 859) Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
6. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.

Items 9-15, 17-23: RH and LH Camshaft Assembly Note

Scheme 760

1. Position the camshafts on the camshaft journals.
2. Install the RH camshaft bearing caps. Position the bearing caps. Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. (Scheme 862) Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
3. Install the LH camshaft bearing caps. Position the bearing caps. Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. (Scheme 863) Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
4. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-207553-S24807556192005113000000) in this section.
5. If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-207553-S28731278102005113000000) in this section.

Item 24-52: Timing Drive Components Assembly Note

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

1. Install the engine lifting equipment and remove the engine from the stand.
2. Position the rear oil seal with the protective installer onto the end of the crankshaft.
3. Using the special tools, install the rear main seal.
4. Install the flexplate and tighten the bolts in two stages in the sequence shown. (Scheme 867) Stage 1: Tighten to 15 N.m (11 lb-ft). Stage 2: Tighten to 110 N.m (81 lb-ft).
5. Mount the engine on a suitable engine stand and remove the engine lifting equipment.
6. Remove the crankshaft position (CKP) sensor and the torque converter cover.
7. Install the special tool. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position. Install the special tool.
8. Install the crankshaft sprocket.
9. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
10. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
11. Remove the locking pin from the LH secondary timing chain tensioner.
12. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
13. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
14. Remove the locking pin from the RH secondary timing chain tensioner.
15. Reset the timing chain tensioners. Hold the lever toward the tensioner piston. Using finger pressure, compress the tensioner. Push the lever down and install a drill rod to lock the piston.
16. Install the special tool on the LH head.
17. Position the LH timing chain and crankshaft gear. Position the timing chain over the LH intake camshaft sprocket. Position the crankshaft gear in the timing chain.
18. Install the LH timing chain guide.
19. Install the LH timing chain tensioner arm.
20. Install the LH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
21. Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages: Stage 1: Tighten to 35 N.m (26 lb-ft). Stage 2: Tighten an additional 90 degrees.
22. Remove the special tool.
23. Install the special tool on the right cylinder head.
24. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
25. Install the RH timing chain guide.
26. Install the RH timing chain tensioner arm.
27. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
28. Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages: Stage 1: Tighten to 35 N.m (26 lb-ft). Stage 2: Tighten an additional 90 degrees.
29. Remove the special tool.
30. Remove the special tool.
31. Install the CKP sensor and the torque converter cover.

Items 53 and 56: Variable Cam Timing (VCT) Bush Carrier Assembly Note

1. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.

Item 59: Sump Body Assembly Note

Scheme 783

Scheme 784

1. Apply three continuous beads of silicone gasket and sealant to the areas shown.
2. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in two stages. Tighten the bolts to 15 N.m (11 lb-ft). Tighten the bolts to 25 N.m (18 lb-ft).
3. Install a new gasket, the oil pump and the bolts.
4. Install the oil pump screen cover and tube.

Items 60 and 61: Engine Front Cover Assembly Note

Scheme 785

1. Apply silicone gasket and sealant in eight places.
2. Install the engine front cover. Install new gaskets. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. see scheme 471 Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
3. Install the coolant pump. Inspect the O-ring seal and install a new O-ring seal as necessary. Position a new coolant pump gasket. Position the coolant pump. Install the bolts and tighten in two stages. Stage 1: Tighten to 8 N.m (71 lb-in). Stage 2: Tighten an additional 90 degrees.

Items 63-64 and 69-70: Exhaust Manifold Assembly Note

1. Install the exhaust manifold. Install a new gasket and the exhaust manifold. Tighten the eight nuts in the sequence shown.

Items 83-90: RH and LH Valve Cover Assembly Note

1. Inspect and install new gaskets as necessary.
2. Apply four beads of silicone gasket and sealant as shown. see scheme 475
3. Install the valve covers. Tighten the bolts in the sequence shown. see scheme 476

Items 92-94: Intake Manifold Assembly Note

Scheme 786

Scheme 787

1. Install new intake manifold gaskets.
2. Install the intake manifold and tighten the bolts in the sequence shown.
3. Connect the throttle body heater hose.
4. Install the radio interference capacitor and the nut.

Item 105: Front Crankshaft Seal Assembly Note

Scheme 788

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

Items 106-108: Crankshaft Pulley Assembly Note

Scheme 789

1. Apply silicone gasket and sealant to the crankshaft pulley keyway.
2. Using the special tool, install the crankshaft pulley.
3. Install the washer and a new bolt and tighten in two stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Tighten an additional 80 degrees. Remove the flexplate holding tool.

Item 114: EGR System Module Gasket Assembly Note

Scheme 790

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

Item 130: Oil Level Indicator Tube Assembly Note

1. Install a new O-ring seal and the oil level indicator tube. Lubricate the new O-ring seal and engine mating surface with clean engine oil.

Item 134: Engine Wiring Harness Assembly Note

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

1. Install the wiring harness onto the front cover.
2. Install the wiring harness onto the front cover.
3. Connect the crankshaft position (CKP) sensor electrical connector.
4. Install the exhaust gas oxygen sensor (HO2S) connectors onto the brackets.
5. Connect the pin-type retainers.
6. Connect the A/C electrical connector and the retaining clip.
7. Connect the power steering pressure (PSP) switch.
8. Connect the variable cam timing (VCT) sensor electrical connector.
9. Install the nuts and the engine wiring harness retainer.
10. Connect the fuel injector and radio interference capacitor electrical connectors.
11. Connect the engine wiring harness retainers from the engine appearance cover support bracket.

Items 135 and 137: RH and LH Coil Cover Assembly Note

Scheme 798

Scheme 799

Scheme 800

Scheme 801

1. Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
2. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.
3. Install the coil cover.
4. Connect the wiring harness retainers to the RH valve cover.
5. Connect the wiring harness retainers to the RH valve cover.

Items 158 and 159: Oil Filter and Seal Assembly Note

1. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Scheme 802

MATERIAL SPECIFICATION

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

1. To install individual components, carry out only the listed steps. INDIVIDUAL COMPONENTS REMOVING STEPS Component Steps LH cylinder head 1-3, 15-65, 72-147 RH cylinder head 4-14, 23-59, 66-147
2. Illustration 1 of 20. Install the components in the order indicated in the following illustration and table. see scheme 502
3. Illustration 2 of 20. Install the components in the order indicated in the following illustration and table. see scheme 503
4. Illustration 3 of 20. Install the components in the order indicated in the following illustration and table. see scheme 504
5. Illustration 4 of 20. Install the components in the order indicated in the following illustration and table. see scheme 505
6. Illustration 5 of 20. Install the components in the order indicated in the following illustration and table. see scheme 506
7. Illustration 6 of 20. Install the components in the order indicated in the following illustration and table. see scheme 507
8. Illustration 7 of 20. Install the components in the order indicated in the following illustration and table. see scheme 508
9. Illustration 8 of 20. Install the components in the order indicated in the following illustration and table. see scheme 509
10. Illustration 9 of 20. Install the components in the order indicated in the following illustration and table. see scheme 510
11. Illustration 10 of 20. Install the components in the order indicated in the following illustration and table. see scheme 511
12. Illustration 11 of 20. Install the components in the order indicated in the following illustration and table. see scheme 512
13. Illustration 12 of 20. Install the components in the order indicated in the following illustration and table. see scheme 513
14. Illustration 13 of 20. Install the components in the order indicated in the following illustration and table. see scheme 514
15. Illustration 14 of 20. Install the components in the order indicated in the following illustration and table. see scheme 515
16. Illustration 15 of 20. Install the components in the order indicated in the following illustration and table. see scheme 516
17. Illustration 16 of 20. Install the components in the order indicated in the following illustration and table. see scheme 517
18. Illustration 17 of 20. Install the components in the order indicated in the following illustration and table. see scheme 518
19. Illustration 18 of 20. Install the components in the order indicated in the following illustration and table. see scheme 519
20. Illustration 19 of 20. Install the components in the order indicated in the following illustration and table. see scheme 520
21. Illustration 20 of 20. Install the components in the order indicated in the following illustration and table. see scheme 521
22. Remove the engine from the engine stand.
23. Install the engine. For additional information, refer to «ENGINE»(ref-207553-S21186689152005113000000) under INSTALLATION in this section.

Items 1-6: RH and LH Cylinder Head Installation Note

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

1. Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
2. Position the cylinder heads. Install new gaskets.
3. Install and tighten the RH head bolts in four stages in the sequence shown. see scheme 523 Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
4. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.
5. Install and tighten the LH head bolts in four stages in the sequence shown. see scheme 525 Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft). Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft). Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees. Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
6. Install and tighten the bolts in two stages. Tighten to 20 N.m (15 lb-ft). Tighten an additional 90 degrees.

Items 7-22: RH and LH Camshaft Installation Note

Scheme 824

1. Position the camshafts on the camshaft journals.
2. Install the RH camshaft bearing caps. Position the bearing caps. Install the bolts. Tighten the bolts in three stages in the sequence shown. see scheme 528 Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
3. Install the LH camshaft bearing caps. Position the bearing caps. Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. see scheme 529 Stage 1: Hand-tighten. Stage 2: Tighten to 6 N.m (53 lb-in). Stage 3: Tighten an additional 90 degrees.
4. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-207553-S24807556192005113000000) in this section.
5. If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to «VALVE CLEARANCE ADJUSTMENT»(ref-207553-S28731278102005113000000) in this section.

Items 24-30, : LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

Scheme 825

Scheme 826

Scheme 827

1. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the LH secondary timing chain tensioner.

Items 31-37: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note

Scheme 828

Scheme 829

Scheme 830

1. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
2. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
3. Remove the locking pin from the RH secondary timing chain tensioner.

Items 38-51: Timing Drive Components Installation Note

Scheme 831

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

1. Reset the timing chain tensioners. Hold the lever toward the tensioner piston. Using finger pressure, compress the tensioner. Push the lever down and install a drill rod to lock the piston.
2. Install the special tool on the LH head.
3. Position the LH timing chain and crankshaft gear. Position the timing chain over the LH intake camshaft sprocket. Position the crankshaft gear in the timing chain.
4. Install the LH timing chain guide.
5. Install the LH timing chain tensioner arm.
6. Install the LH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
7. Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages: Stage 1: Tighten to 35 N.m (26 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Remove the special tool.
9. Install the special tool on the right cylinder head.
10. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
11. Install the RH timing chain guide.
12. Install the RH timing chain tensioner arm.
13. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts. Remove the drill rod.
14. Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages: Stage 1: Tighten to 35 N.m (26 lb-ft). Stage 2: Tighten an additional 90 degrees.
15. Remove the special tool.
16. Remove the special tool.
17. Install the crankshaft position (CKP) sensor.

Items 52 and 55: Variable Cam Timing (VCT) Bush Carrier Installation Note

1. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.

Items 58 and 59: Engine Front Cover Installation Note

Scheme 845

1. Apply silicone gasket and sealant in eight places.
2. Install the engine front cover. Install new gaskets. Position the engine front cover on the cylinder block. Loosely install the bolts. Tighten the bolts in two stages in the sequence shown. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).

Items 61-62 and 67-68: Exhaust Manifold Installation Note

Scheme 846

1. Install the exhaust manifold. Install a new gasket and the exhaust manifold. Tighten the eight nuts in the sequence shown.

Item 67: RH Exhaust Manifold Installation Note

Scheme 847

1. Install the EGR tube. Install a new EGR tube gasket. Install the EGR tube. Install the EGR tube nuts.

Items 72-79: RH and LH Valve Cover Installation Note

Scheme 848

1. Inspect and install new gaskets as necessary.
2. Apply four beads of silicone gasket and sealant as shown. see scheme 559
3. Install the valve covers. Tighten the bolts in the sequence shown.

Items 81-83: Intake Manifold Installation Note

Scheme 849

Scheme 850

1. Install new intake manifold gaskets.
2. Install the intake manifold and tighten the bolts in the sequence shown.
3. Install the radio interference capacitor and the nut.

Item 96: EGR System Module Installation Note

Scheme 851

1. Connect the EGR system module-to-exhaust manifold tube from the EGR system module.

Item 103: Engine Wiring Harness Installation Note

Scheme 852

Scheme 853

Scheme 854

Scheme 855

Scheme 856

Scheme 857

1. Install the wiring harness onto the front cover.
2. Install the wiring harness onto the front cover.
3. Connect the crankshaft position (CKP) sensor electrical connector.
4. Install the exhaust gas oxygen sensor (HO2S) connectors onto the brackets.
5. Connect the two pin-type retainers.
6. Connect the variable cam timing (VCT) sensor electrical connector.
7. Install the engine wiring harness retainer.
8. Connect the fuel injector and radio interference capacitor electrical connectors.
9. Connect the ignition coil electrical connectors.
10. Connect the EGR system module electrical connector.
11. Connect the generator electrical connector.
12. Connect the engine wiring harness retainers to the RH engine appearance cover support bracket.

Items 106 and 107: Engine Cover Support Bracket Installation Note

Scheme 858

1. Install the engine wiring harness retainers onto the engine cover support bracket.

Item 109: Oil Level Indicator Tube Installation Note

1. Install a new O-ring seal and the oil level indicator tube. Lubricate the new O-ring seal and engine mating surface with clean engine oil.

Items 122-125: RH and LH Coil Cover Installation Note

Scheme 859

Scheme 860

Scheme 861

Scheme 862

1. Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
2. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.
3. Install the coil cover.
4. Connect the wiring harness retainers to the RH valve cover.
5. Connect the wiring harness retainers to the RH valve cover.

Item 129: Front Crankshaft Seal Installation Note

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

Items 130-132: Crankshaft Pulley Installation Note

Scheme 863

Scheme 864

1. Apply silicone gasket and sealant to the crankshaft pulley keyway.
2. Using the special tool, install the crankshaft pulley.
3. Install the washer and a new bolt and tighten in two stages. Stage 1: Tighten to 80 N.m (59 lb-ft). Stage 2: Tighten an additional 80 degrees.

Item 134: Coolant Pump Pulley Bolt Installation Note

1. Do not tighten coolant pump pulley bolts until after the accessory drive belt has been installed.

Items 144 and 145: Oil Filter and Seal Installation Note

1. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Scheme 865

MATERIAL SPECIFICATION

Scheme 866

Scheme 867

Scheme 868

Scheme 869

Scheme 870

Scheme 871

Scheme 872

Scheme 873

Scheme 874

Scheme 875

Scheme 876

Scheme 877

Scheme 878

Scheme 879

1. Install the parts in the order indicated in the following illustrations and tables.
2. Install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-207547) .
3. Install the three-way catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207558) .
4. Install the front wheels and tires.
5. Install the fresh air filter panel. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .
6. Install the air cleaner inlet. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) for additional information.
7. Connect the battery ground cable.
8. Fill the engine with clean engine oil.
9. Fill the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-207554) .
10. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .
11. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-207561) .

Item 1: Engine-to-Transmission Bolts Installation Note

1. Install the engine to the transmission and install the bolts.

Item 5: Engine and Transmission Assembly Installation Note

1. Using a floor crane and the special tool, install the engine onto the subframe.

Item 16: Engine and Transmission Assembly Installation Note

Scheme 880

Scheme 881

1. Remove the special tool.
2. Remove the special tool.

Item 26: Block Heater Electrical Connector Installation Note

Scheme 882

1. Connect the engine block heater electrical connector.

Item 28: Engine and Transmission Assembly Installation Note

Scheme 883

1. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
2. Install lower air deflector.

Item 33: Engine and Transmission Assembly Installation Note

1. Remove the safety stands from the rear of the vehicle.

Item 49: Steering Rack Electrical Connectors Installation Note

Scheme 884

1. Connect the power steering rack electrical connectors.

Item 50: Shift Cable Installation Note

Scheme 885

1. Reclip the shift cable to the bracket.

Item 51: Shift Cable Installation Note

Scheme 886

1. Connect the shift cable to the shifter.

Items 55 and 62: Brake Caliper Installation Note

1. Install the brake caliper.

Items 57 and 64: Anti-Lock Brake Sensor Harness Installation Note

Scheme 887

1. Position the anti-lock brake sensor harness and clip to the brake hose.

Items 58 and 65: Anti-Lock Brake Sensor Electrical Connector Installation Note

Scheme 888

Scheme 889

1. Connect the wheel speed sensor electrical connector.
2. Install the inner splash shield. Position the inner splash shield back. Install the pin-type retainers.

Item 66: Low Pressure Hose Installation Note

Scheme 890

1. Connect the A/C low pressure hose.

Item 83: Coolant Valve Electrical Connector Installation Note

Scheme 891

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

Item 84: Heater Hoses Installation Note

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

Item 90: Vapor Management Valve (VMV) Vapor Tube Installation Note

Scheme 892

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

Item 91: Power Steering Pump Reservoir Bolts Installation Note

Scheme 893

1. Position back the power steering pump reservoir and install the bolts.