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Engine Mechanical - 3.7L: Removal & Installation Lincoln MKS I

Mechanical 313 illustrations ~9953 words

Removal

  1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .
  2. Disconnect the Throttle Body (TB) electrical connector.
  3. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
  4. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  5. Disconnect the brake booster vacuum hose from the intake manifold.
  6. Disconnect the PCV tube from the PCV valve.
  7. Detach the wiring harness retainers from the upper intake manifold.
  8. Remove the upper intake manifold support bracket bolt.
  9. Remove the fuel tube bracket bolt.
  10. Remove the 6 bolts and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

Scheme 1

Scheme 1: Installation
Scheme 1: Installation
  1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  2. Install the fuel tube bracket bolt. Tighten to 6 Nm (53 lb-in).
  3. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
  4. Attach the wiring harness retainers to the upper intake manifold.
  5. Connect the PCV tube to the PCV valve.
  6. Connect the brake booster vacuum hose to the intake manifold.
  7. Connect the EVAP tube to the intake manifold.
  8. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  9. Connect the TB electrical connector.
  10. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .

Scheme 2

Scheme 2: Lower Intake Manifold
Scheme 2: Lower Intake Manifold
ItemPart NumberDescription
1W503279Thermostat housing-to-lower intake manifold bolt (3 required)
28A571Thermostat housing gasket
3W503279Lower intake manifold bolt (10 required)
49K461Lower intake manifold
59439Lower intake manifold gasket (8 required)

ITEM DESCRIPTION CHART

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

  1. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L GTDI/3.7L»(ref-376043) .
  2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  3. Remove the 3 thermostat housing-to-lower intake manifold bolts.
  4. Remove the 10 bolts and the lower intake manifold. Remove and discard the intake manifold and thermostat housing gaskets. Clean and inspect all sealing surfaces.

Scheme 3

Scheme 3: Installation
Scheme 3: Installation
  1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  2. Install the 3 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
  3. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L GTDI/3.7L»(ref-376043) .
  4. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-376040) .

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 4

Scheme 4: Removal
Scheme 4: Removal
  1. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L GTDI/3.7L»(ref-376041) .
  2. Remove the oil level indicator.
  3. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.
  4. Detach all of the wiring harness retainers from the LH valve cover stud bolts.
  5. Remove the engine cover stud from the valve cover stud bolt.
  6. Disconnect the 3 LH fuel injector electrical connectors. Early build vehicles
  7. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket. Late build vehicles
  8. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
  9. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
  10. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

Installation

All vehicles

Scheme 5

Scheme 5: Installation
Scheme 5: Installation

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Scheme 6
Scheme 6
  1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints. Late build vehicles
  3. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Early build vehicles
  4. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
  5. Connect the 3 LH fuel injector electrical connectors.
  6. Install the engine cover stud to the valve cover stud bolt. Tighten to 6 Nm (53 lb-in).
  7. Attach all of the wiring harness retainers to the LH valve cover stud bolts.
  8. Connect the LH VCT solenoid electrical connector.
  9. Install the oil level indicator.
  10. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L GTDI/3.7L»(ref-376041) .

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 7

Scheme 7: Removal
Scheme 7: Removal
  1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L GTDI/3.7L»(ref-376041) .
  2. Detach and disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
  3. Detach and disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
  4. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
  5. Disconnect the 3 RH fuel injector electrical connectors.
  6. Detach all of the wiring harness retainers from the RH valve cover stud bolts.
  7. Remove the nut and the Power Steering Pressure (PSP) tube bracket from the valve cover stud bolt. Early build vehicles
  8. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
  9. Loosen the 9 studs bolts and remove the RH valve cover. Discard the gasket. All vehicles
  10. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
  11. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

All vehicles

Scheme 8

Scheme 8: Installation
Scheme 8: Installation

Scheme 9

Scheme 9
Scheme 9
  1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints. Late build vehicles
  3. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Early build vehicles
  4. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
  5. Install the PSP tube bracket on the valve cover stud bolt and install the nut. Tighten to 7 Nm (62 lb-in).
  6. Attach all of the wiring harness retainers to the RH valve cover stud bolts.
  7. Connect the 3 RH fuel injector electrical connectors.
  8. Connect the RH VCT solenoid electrical connector.
  9. Connect the RH CMS electrical connector.
  10. Connect the RH HO2S electrical connector.
  11. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L GTDI/3.7L»(ref-376041) .

Scheme 10

Scheme 10: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
Scheme 10: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
ItemPart NumberDescription
1W701512Crankshaft pulley bolt
2N806165Washer
36316Crankshaft pulley
46700Crankshaft front seal

ITEM DESCRIPTION CHART

  1. For additional information, refer to the appropriate procedure(s).
  1. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
  2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-375983-S35111463032010103100000) .

Scheme 11

Scheme 11: Lower End Components - Exploded View, Flexplate and Crankshaft Rear Seal
Scheme 11: Lower End Components - Exploded View, Flexplate and Crankshaft Rear Seal
ItemPart NumberDescription
1W701559Flexplate bolt (8 required)
26375Flexplate
312A227Crankshaft sensor ring
46701Crankshaft rear seal

ITEM DESCRIPTION CHART

  1. For additional information, refer to the appropriate procedure(s).

Removal and Installation

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-375987) .
  2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50/6F55»(ref-375986) .
  3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
  4. To install, reverse the removal procedure.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

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Scheme 12: Removal
Scheme 12: Removal

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  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-375987) .
  2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-375996) .
  3. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .
  4. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-375990) .
  5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-375999) .
  6. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  7. Remove the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-376045) .
  8. Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
  9. Remove the nut and the A/C tube-to-receiver/drier. Discard the O-ring seal and gasket seal.
  10. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
  11. Remove the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-376031) .
  12. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
  13. Using the 3 Jaw Puller, remove the crankshaft pulley.
  14. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
  15. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  16. Disconnect the hose from the power steering reservoir.
  17. Remove the RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-375983-S17384705352010103100000) and «VALVE COVER - RH»(ref-375983-S17064822752010103100000) .
  18. Remove the bolt and the ground cable.
  19. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
  20. Remove the PSP tube bracket-to-power steering pump bolt.
  21. Remove the 3 bolts and position aside the power steering pump.
  22. Position a floor jack with a block of wood under the front of the oil pan.
  23. Remove the nut, bolt and engine mount brace.
  24. Remove the 4 engine mount nuts.
  25. Remove the 3 bolts and the engine mount.
  26. Remove the 2 bolts and the engine mount bracket.
  27. Remove the 2 engine mount studs.
  28. Remove the 2 upper engine mount bracket bolts.
  29. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
  30. Detach the A/C tube and wiring harness from the retainers.
  31. Remove the A/C tube bracket bolt.
  32. Remove the A/C tube retaining clamp bolt.
  33. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes. Discard the O-ring seals.
  34. Using the floor jack, raise the engine slightly.
  35. Remove the 22 engine front cover bolts.
  36. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.

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Scheme 36: Installation
Scheme 36: Installation

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  1. Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
  2. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  3. Install the Alignment Pins.
  4. Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  5. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
  6. Remove the Alignment Pins.
  7. Install the engine mount bracket and lower bolt. Do not tighten at this time.
  8. Install the 2 upper engine mount bracket bolts. Do not tighten at this time.
  9. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  10. Using the floor jack, lower the engine to the installed position.
  11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt. Tighten to 8 Nm (71 lb-in).
  12. Install the A/C tube retaining clamp bolt. Tighten to 9 Nm (80 lb-in).
  13. Install the A/C tube bracket bolt. Tighten to 15 Nm (133 lb-in).
  14. Attach the A/C tube and wiring harness to the retainers.
  15. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in).
  16. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  17. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  18. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  19. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
  20. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  21. Install the Power Steering Pressure (PSP) tube bracket-to-power steering pump bolt. Tighten to 10 Nm (89 lb-in).
  22. Connect the PSP switch electrical connector.
  23. Install the ground cable bolt. Tighten to 12 Nm (106 lb-in).
  24. Install the RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-375983-S17384705352010103100000) and «VALVE COVER - RH»(ref-375983-S17064822752010103100000) .
  25. Connect the hose to the power steering reservoir.
  26. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
  27. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  28. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
  29. Install the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-376031) .
  30. Connect the power steering cooler tube.
  31. Using a new O-ring seal and gasket seal, install the A/C tube and the nut. Tighten to 15 Nm (133 lb-in).
  32. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut. Tighten to 15 Nm (133 lb-in).
  33. Install the EVAP canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-376045) .
  34. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  35. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-375999) .
  36. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-375990) .
  37. Install the engine ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .
  38. Fill the engine with clean engine oil.
  39. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS)»(ref-375997) .
  40. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-375996) .

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

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Scheme 61: Removal
Scheme 61: Removal

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  1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-375983-S15503032362010103100000) . Engines equipped with early build RH timing chain guides
  2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
  3. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
  4. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
  5. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  6. Remove the 3 bolts and the RH VCT housing.
  7. Remove the 3 bolts and the LH VCT housing.
  8. Remove the 2 bolts and the primary timing chain tensioner.
  9. Remove the primary timing chain tensioner arm.
  10. Remove the 2 bolts and the lower LH primary timing chain guide.
  11. Remove the primary timing chain.
  12. Remove the crankshaft timing chain sprocket.
  13. Remove the 2 bolts and the upper LH primary timing chain guide.
  14. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  15. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  16. Remove the 2 bolts and the LH secondary timing chain tensioner.
  17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  18. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  19. Remove the 2 bolts and the RH secondary timing chain tensioner. Engines equipped with early build RH timing chain guides
  20. Remove the 2 bolts and the RH primary timing chain guide. Engines equipped with late build/replacement RH timing chain guides
  21. Remove the 2 bolts and the RH primary timing chain guide.

Engines equipped with late build/replacement RH timing chain guides

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Scheme 77: Installation
Scheme 77: Installation

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  1. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with early build RH timing chain guides
  2. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
  3. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  4. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  5. Position the RH secondary timing assembly onto the camshafts.
  6. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  7. Remove the lockpin from the RH secondary timing chain tensioner.
  8. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  9. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  10. Position the LH secondary timing assembly onto the camshafts.
  11. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  12. Remove the lockpin from the LH secondary timing chain tensioner.
  13. Install the crankshaft timing chain sprocket.
  14. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  15. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  16. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  17. Install the primary timing chain tensioner arm.
  18. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  19. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  20. As a post-check, verify correct alignment of all timing marks.
  21. Inspect the VCT housing seals for damage and replace as necessary.
  22. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  23. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  24. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-375983-S15503032362010103100000) .
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-375987) .
  2. Remove and discard the engine oil filter. To install, tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  3. Remove the 3 bolts and the oil filter adapter. Discard the gasket. Clean and inspect all sealing surfaces. To install, tighten to 10 Nm (89 lb-in).
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-375987) .
  2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
  3. Remove the EOP switch. To install, tighten to 18 Nm (159 lb-in).
  4. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.
  1. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-375994) .
  2. Remove the LH Heated Oxygen Sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-376038) .
  3. Remove the 3 bolts and the LH exhaust manifold heat shield.
  4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
  5. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-375993) .
  6. Remove and discard the 6 LH exhaust manifold studs.
  7. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Scheme 100

Scheme 100: Installation
Scheme 100: Installation
  1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
  2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
  3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  4. Install the LH HO2S . For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-376038) .
  5. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-375994) .
  1. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-375994) .
  2. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
  3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
  4. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-375993) .
  5. Remove and discard the 6 RH exhaust manifold studs.
  6. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Scheme 101

Scheme 101: Installation
Scheme 101: Installation
  1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
  2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
  3. Connect the RH HO2S electrical connector.
  4. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-375994) .
  1. Position a floor jack with a block of wood under the front of the oil pan.
  2. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  3. Remove the nut, bolt and engine mount brace.
  4. Remove the 4 engine mount nuts.
  5. Remove the 4 engine mount studs.
  6. Remove the 3 bolts and the engine mount.
  1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
  2. Install the engine mount and the 3 bolts. Do not tighten the bolts at this time.
  3. Install the engine mount studs in the following sequence. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 4 engine mount studs. Tighten to 20 Nm (177 lb-in).
  4. Tighten the 3 engine mount bolts to 90 Nm (66 lb-ft).
  5. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  6. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
  7. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

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  1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-375983-S15503032362010103100000) . Engines equipped with early build RH timing chain guides
  2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
  3. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
  4. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
  5. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  6. Remove the 3 bolts and the RH VCT housing.
  7. Remove the 3 bolts and the LH VCT housing.
  8. Remove the 2 bolts and the primary timing chain tensioner.
  9. Remove the primary timing chain tensioner arm.
  10. Remove the 2 bolts and the lower LH primary timing chain guide.
  11. Remove the primary timing chain.
  12. Remove the crankshaft timing chain sprocket.
  13. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
  14. Remove the 3 bolts and the oil pump.

Scheme 113

Scheme 113: Installation
Scheme 113: Installation

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  1. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  2. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  3. Install the crankshaft timing chain sprocket.
  4. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  5. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  6. Install the primary timing chain tensioner arm.
  7. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  9. As a post-check, verify correct alignment of all timing marks.
  10. Inspect the VCT housing seals for damage and replace as necessary.
  11. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  13. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-375983-S15503032362010103100000) .

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All camshafts

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  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-375987) .
  2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-375996) .
  3. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-376031) .
  4. Detach the brake booster vacuum hose retainer from the strut tower brace.
  5. Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
  6. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-376044) .
  7. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .
  8. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-376024) .
  9. Disconnect the engine wiring harness electrical connector.
  10. Remove the nut and disconnect the 2 power feed wires from the positive battery terminal.
  11. Remove the nut and disconnect the ground cable from the negative battery terminal.
  12. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  13. Remove the LF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-375990) .
  14. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-375999) .
  15. Remove the 7 pushpins, 5 screws and the front valance.
  16. Disconnect the power steering cooler tube located at the left front subframe and drain the power steering fluid into a suitable container.
  17. Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
  18. Remove the nut and the A/C tube. Discard the O-ring seal and gasket seal.
  19. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  20. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
  21. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  22. Remove the EVAP canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-376045) .
  23. Disconnect the PCM and engine harness electrical connectors. Detach the wiring harness retainer.
  24. Disconnect the 2 PCM electrical connectors.
  25. Remove the engine wiring harness retainer from the bulkhead. Push the wiring harness retainer tab in. Slide the wiring harness up and out of the bulkhead.
  26. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  27. Disconnect the transaxle control cable from the control lever.
  28. Disconnect the transaxle control cable from the shift cable bracket and detach the wiring harness pin-type retainer.
  29. If equipped, detach the engine block heater harness from the radiator support.
  30. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
  31. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-376044) .
  32. Detach the engine wiring harness retainer.
  33. Detach the wire harness retainer from the RH valve cover stud bolt.
  34. Remove the bolt and the ground cable from the engine.
  35. Disconnect the hose from the power steering reservoir.
  36. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  37. Remove the RH and LH halfshaft nuts. Do not discard at this time.
  38. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
  39. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
  40. Remove the bolt from the RH brake hose bracket.
  41. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
  42. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
  43. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts. All-Wheel Drive (AWD) vehicles
  44. Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire. All camshafts
  45. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  46. Remove and discard the engine oil filter.
  47. Remove the Power Steering Pressure (PSP) tube bracket-to-steering gear bolt.
  48. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
  49. Remove the 2 rear engine roll restrictor-to-transaxle bolts.
  50. Remove the 2 front engine roll restrictor-to-transaxle bolts.
  51. Remove and discard the upper stabilizer link nuts.
  52. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
  53. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the lower ball joints from the wheel knuckles.
  54. Position the Powertrain Lift under the subframe assembly.
  55. Remove the subframe bracket-to-body bolts.
  56. Remove the rear subframe bolts and the subframe brackets.
  57. Remove the front subframe bolts.
  58. Lower the subframe assembly from the vehicle.
  59. Pull the RH wheel knuckle outward and rotate it toward the rear of the vehicle. Secure the RH wheel knuckle assembly.
  60. Remove the 2 intermediate shaft bracket nuts.
  61. Remove the intermediate and halfshaft assembly.
  62. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
  63. Remove and discard the circlip from the stub shaft.
  64. Remove the 2 RH halfshaft support bracket studs.
  65. Remove the 4 bolts and the RH halfshaft support bracket.
  66. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  67. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
  68. Install the Powertrain Lift and Universal Adapter Brackets.
  69. Remove the transaxle mount through bolt and nut.
  70. Remove the bolt, 3 nuts and the transaxle mount bracket.
  71. Remove the nut, bolt and engine mount brace.
  72. Remove the 4 engine mount nuts.
  73. Remove the 3 bolts and the engine mount.
  74. Lower the engine and transaxle assembly from the vehicle.
  75. Disconnect the PCV hose from the PCV valve.
  76. Disconnect the Throttle Body (TB) electrical connector.
  77. Detach the wiring harness retainers from the upper intake manifold.
  78. Remove the upper intake manifold support bracket bolt.
  79. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
  80. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
  81. Disconnect the RH catalyst monitor electrical connector.
  82. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
  83. Disconnect the 3 RH coil-on-plug electrical connectors.
  84. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  85. Disconnect the LH VCT solenoid electrical connector.
  86. Disconnect the 3 LH coil-on-plug electrical connectors.
  87. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  88. Remove the 6 bolts and the 6 coil-on-plug assemblies.
  89. Disconnect the PSP switch electrical connector.
  90. Remove the PSP tube bracket-to-power steering pump bolt.
  91. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
  92. Remove the 3 bolts and position aside the power steering pump.
  93. Remove the 3 bolts and the accessory drive belt tensioner.
  94. Remove the engine cover stud from the LH valve cover stud bolt. Early build vehicles
  95. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
  96. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
  97. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
  98. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
  99. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
  100. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
  101. Using the 3 Jaw Puller, remove the crankshaft pulley.
  102. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
  103. Remove the 2 bolts and the engine mount bracket.
  104. Remove the 2 engine mount studs.
  105. Remove the 3 bolts and the engine mount bracket.
  106. Remove the 22 engine front cover bolts.
  107. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
  108. Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
  109. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block. Engines equipped with early build RH timing chain guides
  110. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
  111. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
  112. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
  113. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  114. Remove the 3 bolts and the RH VCT housing.
  115. Remove the 3 bolts and the LH VCT housing.
  116. Remove the 2 bolts and the primary timing chain tensioner.
  117. Remove the primary timing chain tensioner arm.
  118. Remove the 2 bolts and the lower LH primary timing chain guide.
  119. Remove the primary timing chain. LH camshafts
  120. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  121. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  122. Remove the Camshaft Holding Tool from the LH camshafts.
  123. Verify the LH camshafts are in the neutral position.
  124. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts. RH camshafts
  125. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  126. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  127. Remove the Camshaft Holding Tool from the RH camshafts.
  128. Rotate the RH camshafts counterclockwise to the neutral position.
  129. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.
WARNINGDo not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All camshafts

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  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position. LH camshafts
  2. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
  3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). RH camshafts
  4. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
  5. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All camshafts
  6. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet (s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-375983-S29344586002010103100000) . LH camshafts
  7. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.
  8. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  9. Position the LH secondary timing assembly onto the camshafts.
  10. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  11. Remove the lockpin from the LH secondary timing chain tensioner. RH camshafts
  12. Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.
  13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  14. Position the RH secondary timing assembly onto the camshafts.
  15. Install the new VCT bolt and new exhaust camshaft bolt and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  16. Remove the lockpin from the RH secondary timing chain tensioner. All camshafts
  17. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  20. Install the primary timing chain tensioner arm.
  21. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  23. As a post-check, verify correct alignment of all timing marks.
  24. Inspect the VCT housing seals for damage and replace as necessary.
  25. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  26. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  27. Install the Alignment Pins.
  28. Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  29. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence shown in illustration to 3 Nm (27 lb-in).
  30. Remove the Alignment Pins.
  31. Install the engine mount bracket and the 3 bolts.
  32. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  33. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in).
  34. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  35. Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
  36. Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  37. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
  38. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
  39. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  40. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
  41. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints. Early build vehicles
  42. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
  43. Using a new gasket, install the RH valve cover and the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
  44. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints. Early build vehicles
  45. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
  46. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
  47. Install the engine cover stud to the LH valve cover stud bolt. Tighten to 6 Nm (53 lb-in).
  48. Install the PSP tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
  49. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  50. Connect the PSP switch electrical connector.
  51. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
  52. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  53. Connect the 3 LH coil-on-plug electrical connectors.
  54. Connect the LH VCT solenoid electrical connector.
  55. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  56. Connect the 3 RH coil-on-plug electrical connectors.
  57. Connect the RH VCT solenoid electrical connector.
  58. Connect the RH CMS electrical connector.
  59. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  60. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer. Tighten to 6 Nm (53 lb-in).
  61. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
  62. Attach the wiring harness retainers to the upper intake manifold.
  63. Connect the Throttle Body (TB) electrical connector.
  64. Connect the PCV hose to the PCV valve.
  65. Raise the engine and transaxle assembly into the vehicle.
  66. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  67. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  68. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (177 lb-in).
  69. Install the transaxle support insulator bracket, 3 nuts and the bolt. Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft). Tighten the transaxle support insulator bolt to 55 Nm (41 lb-ft).
  70. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft). All-Wheel Drive (AWD) vehicles
  71. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-376013) . All camshafts
  72. Connect the transaxle cooler tubes and install the 2 secondary latches.
  73. Install the RH halfshaft support bracket and the 4 bolts. Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft). Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (177 lb-in).
  74. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
  75. Install the correct new circlip on the inboard stub shaft.
  76. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
  77. Rotate the LH wheel knuckle into position and insert the LH halfshaft into the wheel hub.
  78. Install the intermediate and halfshaft assembly and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
  79. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
  80. Using the Powertrain Lift, raise the subframe into the installed position.
  81. Install the 2 front subframe bolts. Tighten to 200 Nm (148 lb-ft).
  82. Position the subframe brackets and install the 4 bolts finger-tight.
  83. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
  84. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
  85. Position the ball joints into the wheel knuckles. Install the new ball joint nuts. Tighten to 200 Nm (148 lb-ft).
  86. Install new tie-rod end nuts. Tighten to 150 Nm (111 lb-ft).
  87. Install new upper stabilizer bar link nuts. Tighten to 150 Nm (111 lb-ft).
  88. Install the 2 front engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
  89. Install the 2 rear engine roll restrictor-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
  90. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
  91. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
  92. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees. AWD vehicles
  93. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown in illustration). Tighten to 70 Nm (52 lb-ft). All camshafts
  94. Using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
  95. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  96. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
  97. Position the RH brake hose bracket and install the bolt. Tighten to 30 Nm (22 lb-ft).
  98. Position the rubber shield and install the 2 lower scrivets.
  99. Using the previously removed RH and LH wheel hub nuts, seat the halfshaft. Tighten to 350 Nm (258 lb-ft). Remove and discard the wheel hub nuts.
  100. Install a new RH and LH wheel hub nut. Tighten to 350 Nm (258 lb-ft).
  101. Connect the hose to the power steering reservoir.
  102. Install the oil level indicator.
  103. Install the ground cable and bolt. Tighten to 12 Nm (106 lb-in).
  104. Attach the wire harness retainer to the RH valve cover stud bolt.
  105. Attach the engine wiring harness retainer.
  106. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-376044) .
  107. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (133 lb-in).
  108. If equipped, attach the block heater wiring harness retainer to the radiator and power steering tube.
  109. Connect the transaxle control cable to the shift cable bracket.
  110. Connect the transaxle control cable to the control lever.
  111. Connect the upper radiator hose, lower radiator hose and heater hose to the thermostat housing.
  112. Install the engine wiring harness retainer to the bulkhead. Slide the wiring harness in the bulkhead. Make sure the wiring harness retainer tab is below the bulkhead lip.
  113. Connect the 2 PCM electrical connectors.
  114. Connect the PCM and engine harness electrical connectors. Attach the wiring harness retainer.
  115. Install the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(ref-376045) .
  116. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  117. Connect the vacuum hose and the EVAP tube to the upper intake manifold.
  118. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  119. Using a new O-ring seal and gasket seal, install the A/C tube and the nut. Tighten to 15 Nm (133 lb-in).
  120. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut. Tighten to 15 Nm (133 lb-in).
  121. Connect the power steering cooler tube.
  122. Install the front valance, 7 pushpins and 5 screws.
  123. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-375999) .
  124. Install the LF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-375990) .
  125. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  126. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  127. Connect the engine wiring harness electrical connector.
  128. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-376024) .
  129. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-376025) .
  130. Install the strut tower brace and the 4 nuts. Tighten to 35 Nm (26 lb-ft).
  131. Attach the brake booster vacuum hose retainers to the strut tower brace.
  132. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-376031) .
  133. Fill the engine with clean engine oil.
  134. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-376040) .
  135. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS)»(ref-375997) .
  136. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-375996) .

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