Engine - 3.5L: Removal & Installation Lincoln MKX I

REMOVAL

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
2. Disconnect the throttle body (TB) electrical connector.
3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
4. Disconnect the brake booster vacuum hose from the intake manifold.
5. Disconnect the PCV tube from the PCV valve.
6. Detach the wiring harness retainers from the upper intake manifold.
7. Remove the upper intake manifold support bracket bolt.
8. Remove the 6 bolts and remove the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

INSTALLATION

1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
3. Attach the wiring harness retainers to the upper intake manifold.
4. Connect the PCV tube to the PCV valve.
5. Connect the brake booster vacuum hose to the intake manifold.
6. Connect the EVAP tube to the intake manifold.
7. Connect the TB electrical connector.
8. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.

Scheme 7

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
3. Remove the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 3.5L»(ref-292566) article.
4. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
5. Remove the 3 thermostat housing-to-lower intake manifold bolts.
6. 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.

1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown 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 air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
4. Install the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 3.5L»(ref-292566) article.
5. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.

1. Remove the crankcase vent tube.
2. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-292563) article.
3. Remove the oil level indicator.
4. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
5. Detach all of the wiring harness retainers from the valve cover and the stud bolts.
6. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
7. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
8. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.

1. Using the special tools, 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.
3. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Attach all of the wiring harness retainers to the valve cover and the stud bolts.
5. Connect the LH VCT solenoid electrical connector.
6. Install the oil level indicator.
7. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-292563) article.
8. Install the crankcase vent tube.

1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-292563) article.
2. Disconnect the power steering pressure (PSP) switch electrical connector.
3. Disconnect the RH catalyst monitor sensor electrical connector and pin-type retainer.
4. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
5. Disconnect the RH variable camshaft timing (VCT) electrical connector.
6. Disconnect the 3 RH fuel injector electrical connectors.
7. Detach all of the wiring harness retainers from the RH valve cover and the stud bolts.
8. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
9. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
10. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.

1. Using the special tools, 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.
3. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Attach all of the wiring harness retainers to the valve cover and the stud bolts.
5. Connect the 3 RH fuel injector electrical connectors.
6. Connect the RH VCT electrical connector.
7. Connect the RH HO2S electrical connector.
8. Connect the RH catalyst monitor sensor electrical connector and pin-type retainer.
9. Connect the PSP switch electrical connector.
10. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-292563) article.

Scheme 8

1. For additional information, refer to the appropriate procedures in this service information.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
3. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
4. Using the special tool, remove the crankshaft pulley.

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft pulley.
3. Using the special tool, 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.
4. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-292564-S16795020982008080400000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

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-292564-S16795020982008080400000) .

Scheme 9

1. For additional information, refer to the appropriate procedures in this service information.

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50»(ref-292543) article.
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove the flexplate. For additional information, refer to «Flexplate»(ref-292564-S07196869772008080400000) .
3. Remove the crankshaft sensor ring.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.

1. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
2. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
3. Install the crankshaft sensor ring.
4. Install the flexplate. For additional information, refer to «Flexplate»(ref-292564-S07196869772008080400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
4. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
5. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
6. Using the special tool, remove the crankshaft pulley.
7. Using the special tool, remove and discard the crankshaft front seal.
8. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
9. Remove the 4 nuts, the exhaust flexible pipe and the Y-pipe as an assembly. Discard the nuts and the gasket.
10. Remove the 2 nuts and the roll restrictor heat shield.
11. Remove the roll restrictor through bolt and the 2 roll restrictor-to-transaxle bracket plate bolts.
12. Loosen the roll restrictor-to-subframe through bolt. Position the roll restrictor and transaxle bracket plate aside.
13. Remove the 3 bolts and the transaxle bracket.
14. Remove and discard the RH front halfshaft nut.
15. Remove the RH stabilizer link-to-lower control arm nut.
16. Remove the RH lower control arm-to-knuckle pinch bolt. Separate the lower control arm from the knuckle.
17. Using the special tool, separate the RH halfshaft from the hub.
18. Using the special tools, separate the RH halfshaft from the intermediate shaft. Remove the RH halfshaft.
19. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
20. If equipped, detach the engine block heater harness from the radiator support, the A/C suction tube and the engine wiring harness.
21. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
22. Remove the LH and RH valve covers. For additional information, refer to «Valve Cover - LH»(ref-292564-S33714080652008080400000) and «Valve Cover - RH»(ref-292564-S40204582622008080400000) .
23. Remove the safety clip from the A/C suction tube fitting. Disconnect the A/C suction tube fitting and position the tube aside.
24. Remove the A/C pressure tube bracket bolt.
25. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal. Position the A/C pressure tube aside.
26. Disconnect the 2 engine wiring harness connectors.
27. Remove the bolt and the ground wire from the engine front cover.
28. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
29. Remove the nut, the ground wire and the radio interference capacitor from the cowl stud.
30. Disconnect the purge valve electrical connector.
31. Disconnect the 3 PCM electrical connectors and position the wiring harness aside.
32. Remove the 3 bolts and position the degas bottle aside.
33. Remove the 2 power steering reservoir nuts. Support the power steering reservoir and hose away from the front of the engine with a length of mechanic's wire.
34. Remove the 3 power steering pump bolts. Support the power steering pump and hose away from the front of the engine with a length of mechanic's wire.
35. Remove the bolts, the LH and the RH VCT solenoids.
36. Position a floor jack and the special tool under the oil pan.
37. Loosen the transaxle mount through bolt.
38. Remove the nut, bolt and engine mount brace.
39. Remove the 4 engine mount nuts.
40. Remove the 3 bolts and the engine mount.
41. Remove the 2 bolts and the engine mount bracket.
42. Remove the 2 engine mount studs.
43. Remove the 2 upper engine mount bracket bolts.
44. Lower the engine to access the lower engine mount bracket bolt.
45. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
46. Remove the 22 engine front cover bolts.
47. 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 criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.

1. Raise the engine to the installed position.
2. 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.
3. 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.
4. Install the special tools.
5. 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.
6. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
7. Remove the special tools (alignment pins).
8. Lower the engine to allow installation of the engine mount bracket and lower bolt. Install the engine mount bracket and lower bolt as an assembly.
9. Raise the engine to the installed position. Install the 2 upper engine mount bracket bolts.
10. 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 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). 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).
11. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
12. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
13. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
14. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
15. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (15 lb-ft).
16. Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).
17. Install the LH and RH VCT solenoids and bolts. Tighten to 10 Nm (89 lb-in).
18. Install the power steering pump and the 3 bolts. Tighten to 24 Nm (18 lb-ft).
19. Install the power steering reservoir and the 2 nuts. Tighten to 8 Nm (71 lb-in).
20. Install the degas bottle and the 3 bolts. Tighten to 9 Nm (80 lb-in).
21. Connect the 3 PCM electrical connectors.
22. Connect the purge valve electrical connector.
23. Install the radio interference capacitor, the ground wire and the nut to the cowl stud. Tighten to 10 Nm (89 lb-in).
24. Install the radio interference capacitor wire, the ground wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
25. Install the ground wire and bolt on the engine front cover. Tighten to 10 Nm (89 lb-in).
26. Connect the 2 engine wiring harness connectors.
27. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
28. Install the A/C pressure tube bracket and bolt. Tighten to 8 Nm (71 lb-in).
29. Connect the A/C suction tube fitting. Install the safety clip onto the fitting.
30. Install the LH and RH valve covers. For additional information, refer to «Valve Cover - LH»(ref-292564-S33714080652008080400000) and «Valve Cover - RH»(ref-292564-S40204582622008080400000) .
31. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
32. If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.
33. Align the RH halfshaft splines with the intermediate shaft and push the halfshaft on until the circlip locks the shafts together. Pull the inboard halfshaft outward to make sure the circlip is locked.
34. Install the RH halfshaft into the hub and install a new halfshaft nut.
35. Install the RH lower ball joint into the steering knuckle and install the pinch bolt. Tighten to 55 Nm (41 lb-ft).
36. Install the RH stabilizer bar link into the lower control arm and install the nut. Tighten to 90 Nm (66 lb-ft).
37. Tighten the RH halfshaft nut to 350 Nm (258 lb-ft).
38. Install and the transaxle bracket and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
39. Position the roll restrictor and transaxle bracket plate and install the 3 bolts. Tighten to 90 Nm (66 lb-ft).
40. Tighten the engine roll restrictor-to-subframe through bolt to 103 Nm (76 lb-ft).
41. Install the roll restrictor heat shield and the 2 nuts. Tighten to 11 Nm (8 lb-ft).
42. Position the Y-pipe assembly in place and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
43. Install the 2 exhaust hangers and tighten the exhaust clamp. Tighten to 40 Nm (30 lb-ft).
44. Using the special tools, install a new crankshaft front seal.
45. Using the special tools, install the crankshaft pulley.
46. Using the special tool, 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.
47. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
48. Fill the engine with clean engine oil.
49. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
50. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.

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 engine front cover. For additional information, refer to «Engine Front Cover»(ref-292564-S32170380892008080400000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
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.
20. Remove the 2 bolts and the RH primary timing chain guide.

1. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
4. Position the RH secondary timing assembly onto the camshafts.
5. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. 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.
6. Remove the lockpin from the RH secondary timing chain tensioner.
7. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Assemble the LH 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 washers. 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.
12. Install the crankshaft timing chain sprocket.
13. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
14. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
15. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
16. Install the primary timing chain tensioner arm.
17. 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.
18. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
19. As a post-check, verify correct alignment of all timing marks.
20. Install new VCT housing seals.
21. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
22. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
23. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292564-S32170380892008080400000) .

Scheme 10

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
3. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292525) article.
4. Disconnect the 2 coolant hoses from the oil cooler.
5. Remove the 6 bolts and the oil cooler. Discard the gaskets. Inspect the oil cooler. Clean and inspect all sealing surfaces.

1. Using new gaskets, install the oil cooler and the 6 bolts. Tighten to 10 Nm (89 lb-in).
2. Connect the 2 coolant hoses to the oil cooler.
3. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292525) article.
4. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove and discard the engine oil filter.
3. If equipped, remove the engine oil cooler. For additional information, refer to «Oil Cooler»(ref-292564-S21206756752008080400000) .
4. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal. Clean and inspect all sealing surfaces.

1. Using a new gasket and O-ring seal, install the oil filter adapter. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
2. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
3. If equipped, install the engine oil cooler. For additional information, refer to «Oil Cooler»(ref-292564-S21206756752008080400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Remove the cooling fan assembly. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
3. Disconnect the engine oil pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 18 Nm (13 lb-ft).
5. 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-292525) article.
2. Remove the LH heated oxygen sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-292567) article.
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-292524) article.
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.

1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
4. Install the LH HO2S. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-292567) article.
5. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292525) article.

1. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292525) article.
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-292524) article.
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.

1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
3. Connect the RH HO2S electrical connector.
4. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292525) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers. To install, tighten to 40 Nm (30 lb-ft).
3. Remove the 4 nuts, the exhaust flexible pipe and the Y-pipe as an assembly. Discard the nuts and the gasket. To install, tighten to 40 Nm (30 lb-ft).
4. Remove the 2 nuts and the roll restrictor heat shield. To install, tighten to 11 Nm (8 lb-ft).
5. Loosen the roll restrictor-to-subframe through bolt. To install, tighten to 103 Nm (76 lb-ft).
6. Remove the roll restrictor through bolt and the 2 roll restrictor-to-transaxle bracket plate bolts. To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 3 bolts and the transaxle bracket. To install, tighten to 90 Nm (66 lb-ft).
8. Position a floor jack and the special tool under the oil pan.
9. Remove the 3 bolts and position the engine coolant degas bottle aside. To install, tighten to 9 Nm (80 lb-in).
10. Remove the nut, bolt and engine mount brace. To install, tighten to 20 Nm (15 lb-ft).
11. Remove the 4 engine mount nuts. To install, tighten to 63 Nm (46 lb-ft).
12. Remove the 3 bolts and the engine mount. To install, tighten to 90 Nm (66 lb-ft).
13. 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.

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292564-S32170380892008080400000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
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 oil pump screen and pickup tube bolts.
14. Remove the 3 oil pump bolts. Rotate the oil pump clockwise and separate the oil pump from the oil pump screen and pickup tube. Remove the oil pump. Discard the oil pump screen and pickup tube O-ring seal.

1. Position the oil pump onto the crankshaft and rotate counterclockwise to position the pump onto the oil pump screen and pickup tube. Install the 3 bolts and tighten to 10 Nm (89 lb-in).
2. Install the 2 oil pump screen and pickup tube 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. Install new VCT housing seals.
11. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
13. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292564-S32170380892008080400000) .

Special Tools Illustration Tool Name Tool Number Disconnect Tool, Transmission Cooler Tube 307-569 Engine Lifting Bracket 303-1245 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Remover, Front Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft (Extension) 205-243 (T89P-3415-A) Remover, Halfshaft (Plate) 205-290 (T89P-3415-B) Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Tie-Rod End Remover 211-105 Universal Adapter Brackets 014-0001

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.
3. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
5. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
6. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
7. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
8. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
9. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
10. Disconnect the battery harness electrical connector.
11. Remove the nut and disconnect the power feed from the battery terminal.
12. Remove the bolt and the ground wire. Detach the 2 wiring harness retainers from the cowl.
13. Disconnect the vacuum hose from the upper intake manifold.
14. Disconnect the upper evaporative emissions (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
15. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
16. Detach the wiring harness retainer from the transaxle control cable bracket.
17. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
18. Disconnect the transaxle control electrical connector.
19. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
20. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal.
21. Remove the safety clip from the A/C fitting. Disconnect the A/C suction tube fitting.
22. Disconnect the hose from the power steering reservoir.
23. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
24. Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.
25. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
26. Remove the oil level indicator.
27. Detach the wiring harness retainer from the RH valve cover stud bolt.
28. Remove the bolt and the ground wire from the engine front cover.
29. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
30. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
31. Remove the 4 nuts and the exhaust flexible pipe and Y-pipe as an assembly. Discard the nuts and the gasket.
32. Remove the 3 pin-type retainers, the 7 screws and the radiator splash shield.
33. Remove the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-292537) article.
34. Remove the 2 secondary latches from the transmission fluid cooler tubes.
35. Using the special tool, disconnect the transmission cooling tubes.
36. Remove the 4 oil pan-to-transaxle bolts.
37. Remove the 2 fasteners and the inspection cover.
38. Remove and discard the 3 torque converter bolts.
39. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
40. Remove and discard the engine oil filter.
41. Remove the power steering cooler bracket bolt from the RH side of the subframe.
42. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
43. Remove and discard the RH front halfshaft nut.
44. Remove the 2 nuts and the roll restrictor heat shield.
45. Remove the engine roll restrictor-to-subframe through bolt.
46. Remove and discard the power steering pressure (PSP) tube-to-pump banjo bolt and the 2 seals.
47. Remove and discard the steering intermediate shaft bolt. Separate the steering intermediate shaft from the steering gear.
48. Remove and discard the cotter pins and tie-rod end nuts. Using the special tool, separate the tie-rod ends from the wheel knuckles.
49. Remove the 2 stabilizer link-to-lower control arm nuts and separate the stabilizer bar links from the lower control arms.
50. Remove the lower control arm-to-knuckle pinch bolts and separate the lower control arms from the knuckles.
51. Remove the 3 RH subframe-to-lower bumper nuts.
52. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
53. Position the special tool under the subframe assembly.
54. Remove the 2 nuts, 4 bolts and the subframe support brackets.
55. Remove the 2 front subframe nuts.
56. Remove the 2 middle subframe nuts.
57. Using the special tool, lower the subframe assembly from the vehicle.
58. If equipped, disconnect the oil cooler coolant hoses.
59. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
60. Remove the 2 RH catalytic converter support bracket bolts.
61. Using the special tool, separate the RH halfshaft from the hub.
62. Remove the bolt, the nut and the RH catalytic converter support bracket.
63. Remove the 2 stud bolts and the RH halfshaft/intermediate shaft assembly.
64. Remove the 2 RH halfshaft bearing support bracket bolts and the RH halfshaft/intermediate shaft assembly.
65. Disconnect the RH catalyst monitor electrical connector.
66. Remove the 4 nuts and the RH catalytic converter. Discard the gasket and the nuts.
67. Remove the 5 bolts and the power transfer unit (PTU) support bracket.
68. Remove the 5 bolts and the PTU.
69. Install the special tools.
70. Remove the transaxle support insulator through bolt and nut.
71. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
72. Remove the nut, bolt and engine mount brace.
73. Remove the 4 engine mount nuts.
74. Remove the 3 bolts and the engine mount.
75. Lower the engine and transaxle assembly from the vehicle.
76. Position the starter cable boot back and remove the 2 nuts. Detach the 2 wire terminals from the starter.
77. Disconnect the wiring harness retainer from the starter motor stud bolt.
78. Remove the bolt, stud bolt and the starter.
79. Install the special tool on the LH cylinder head.
80. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
81. Remove the 2 engine-to-transaxle bolts.
82. Remove the 5 transaxle-to-engine bolts. Separate the transaxle from the engine.