Engine Mechanical - 3.7L: Other Lincoln MKX I рестайлинг

Engine Code Information Label

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

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Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is covered in the INTRODUCTION article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors

1. are mounted between the fuel rail and the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Twin Independent Variable Camshaft Timing (VCT) System

The twin independent VCT system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

PCV System

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

Oil Pump

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

The heart of the system is a positive displacement internal gear oil pump.

Generically, this design is known as a gerotor pump, which operates as follows

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

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Cooling System

The engine cooling system includes the following

1. Radiator
2. Timing chain driven coolant pump
3. Electric fan assembly
4. Degas bottle (aids in maintaining the correct volume of engine coolant)
5. Coolant thermostat
6. Coolant hoses

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . For driveability concerns, refer to the INTRODUCTION article.

Scheme 484

1. Remove the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-494555-S16131633692012081400000) and «VALVE COVER - RH»(ref-494555-S22477061102012081400000) .
2. Use a feeler gauge to measure the clearance of each valve and record its location. A midrange clearance is the most desirable: Intake: 0.15-0.25 mm (0.006-0.01 in) Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
3. If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
4. If required, install the new selected valve tappets in the marked locations. For additional information, refer to «VALVE TAPPETS»(ref-494555-S39868208182012081400000) .

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1. Use only a mild soap and water solution to clean the engine appearance cover.

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Valve Cover - LH

SPECIAL TOOLS CHART Handle 205-153 (T80T-4000-W) Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

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MATERIAL SPECIFICATIONS

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Valve Cover - RH

SPECIAL TOOLS CHART Handle 205-153 (T80T-4000-W) Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

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MATERIAL SPECIFICATIONS

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Crankshaft Pulley

SPECIAL TOOLS CHART 3 Jaw Puller 303-D121 or equivalent Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
3. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

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1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.
3. 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.
4. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
5. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Crankshaft Front Seal

SPECIAL TOOLS CHART Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-494555-S31422447902012081400000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

Flexplate

SPECIAL TOOLS CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Crankshaft Rear Seal

SPECIAL TOOLS CHART Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-494555-S23080431252012081400000) .
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.

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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-494555-S23080431252012081400000) .

Engine Front Cover

SPECIAL TOOLS CHART 3 Jaw Puller 303-D121 or equivalent Alignment Pins 307-399 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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Timing Drive Components

SPECIAL TOOLS CHART Hold Down, Secondary Chain 303-1530 Tool, Camshaft Holding 303-1248

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Engine Oil Pressure (EOP) Switch

MATERIAL SPECIFICATIONS

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Exhaust Manifold - RH

MATERIAL SPECIFICATIONS

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1. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
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-494566) .
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 515

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-494567) .

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1. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
2. Position a floor jack with a block of wood under the front of the oil pan.
3. Remove the 3 bolts and position the engine coolant degas bottle aside.
4. Remove the nut, bolt and engine mount brace.
5. Remove the 4 engine mount nuts.
6. Remove the 3 bolts and the engine mount.

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1. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
2. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
3. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
4. Position the engine coolant degas bottle and install the 3 bolts. Tighten to 9 Nm (80 lb-in).
5. Install the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .

Oil Pan

MATERIAL SPECIFICATIONS

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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.

All Vehicles

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
4. Remove the oil level indicator.
5. Detach the wiring harness retainer from the starter stud bolt. Remove the starter stud bolt.
6. Loosen the 3 upper bellhousing-to-engine bolts 5 mm (0.19 in).
7. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
8. Remove and discard the engine oil filter.
9. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
10. Remove the engine roll restrictor. For additional information refer to, «AUTOMATIC TRANSMISSION - 6F50/6F55»(ref-494558) . All-Wheel Drive (AWD) vehicles
11. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
12. Remove the RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-494563) .
13. Remove the 2 intermediate shaft support bolts, the 5 Power Transfer Unit (PTU) support bracket bolts and the PTU support bracket. All vehicles
14. Remove the A/C compressor nut and stud.
15. Loosen the 3 LH bellhousing-to-engine bolts 5 mm (0.19 in).
16. Loosen the RH engine-to-bellhousing bolt 5 mm (0.19 in).
17. Remove the 2 fasteners and the inspection cover.
18. Remove the 4 oil pan-to-bellhousing bolts.
19. Separate the engine and transaxle 5 mm (0.19 in).
20. Remove the 4 lower engine front cover bolts.
21. Remove the 16 oil pan bolts.
22. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.
23. Clean the engine oil pan 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 oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
24. Clean the sealing surfaces of the cylinder block and engine front cover 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 and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

Crankshaft Rear Seal with Retainer Plate

SPECIAL TOOLS CHART Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-494555-S23080431252012081400000) .
3. Remove the crankshaft sensor ring.
4. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
5. Remove the bolt and the CKP sensor.
6. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
7. Remove the 2 oil pan to crankshaft rear seal retainer bolts.
8. Remove the 8 crankshaft rear seal retainer bolts.
9. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
10. Clean the crankshaft rear seal retainer plate 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 crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
11. Clean the sealing surfaces of the cylinder block and oil pan flange 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.

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1. Apply 5 mm (0.196 in) beads of Motorcraft® High Performance Engine RTV Silicone to the 2 cylinder block/oil pan joints.
2. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
3. Install the crankshaft rear seal retainer at an angle above the oil pan flange to avoid scraping off the sealer. Tilt the seal retainer up and onto the rear of the cylinder block.
4. Install the 8 bolts and tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
5. Install the 2 oil pan to crankshaft rear seal retainer bolts. Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
6. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
7. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
8. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
9. Connect the CKP sensor electrical connector.
10. Install the crankshaft sensor ring.
11. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-494555-S23080431252012081400000) .

SPECIAL TOOLS CHART Tool, Camshaft Holding 303-1248

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Camshaft

SPECIAL TOOLS CHART 3 Jaw Puller 303-D121 or equivalent Adjustable Grip Arm, 1735A 014-00001 Disconnect Tool, Transmission Cooler Tube 307-569 Handle 205-153 (T80T-4000-W) Hold Down, Secondary Chain 303-1530 Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Powertrain Lift 300-OTC1585AE Remover, Oil Seal 303-409 (T92C-6700CH) Remover, Tie-Rod End 211-105 Remover, VCT Spark Plug Tube Seal 303-1247/1 Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248

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MATERIAL SPECIFICATIONS

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.

All vehicles

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
4. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
5. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
7. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
8. Remove the LH halfshaft and intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
9. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
10. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
11. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
12. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
13. Remove the 2 nuts and disconnect the power feed from the battery terminal. Disconnect the wiring harness electrical connector.
14. Remove the nut and the ground wire. Disconnect the wiring harness electrical connector.
15. Detach the 2 wiring harness retainers from the stud bolt and bracket.
16. Disconnect the wiring harness electrical connector.
17. Detach the 3 wiring harness retainers from the bracket and inner fender.
18. Disconnect the vacuum hose from the upper intake manifold.
19. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
20. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
21. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
22. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal.
23. Remove the safety clip from the A/C fitting. Disconnect the A/C suction tube fitting.
24. Disconnect the hose from the power steering reservoir.
25. Disconnect the 2 PCM electrical connectors. Detach the 3 wiring harness retainers.
26. Disconnect the wiring harness electrical connector. Detach the wiring harness retainer from the RH valve cover stud bolt.
27. Remove the oil level indicator.
28. Remove the bolt and the ground wire from the engine front cover.
29. Remove the nut and the radio interference capacitor wire from the engine front cover stud.
30. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
31. Remove the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-494576) .
32. Remove the 2 secondary latches from the transmission fluid cooler tubes.
33. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission cooling tubes.
34. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
35. Remove and discard the engine oil filter.
36. Remove the power steering cooler bracket bolt from the RH side of the subframe. All-Wheel Drive (AWD) vehicles
37. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire. All vehicles
38. Remove the 2 nuts and the roll restrictor heat shield.
39. Remove the engine roll restrictor-to-subframe through bolt.
40. Remove and discard the Power Steering Pressure (PSP) tube-to-steering gear banjo bolt and the 2 seals.
41. Remove and discard the steering intermediate shaft bolt. Separate the steering intermediate shaft from the steering gear.
42. Remove and discard the cotter pins and tie-rod end nuts. Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
43. Remove the 3 RH subframe-to-lower bumper nuts.
44. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
45. Mark the relationship of the front subframe to the underbody at the mounting locations.
46. Position the Powertrain Lift under the subframe assembly.
47. Remove the 2 bolts and the subframe brace.
48. Remove the 2 nuts, 2 bolts and the 2 subframe support brackets.
49. Remove the 2 front subframe nuts.
50. Remove the 2 middle subframe nuts.
51. Using the Powertrain Lift, lower the subframe assembly from the vehicle.
52. Disconnect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
53. Install the Powertrain Lift and Adjustable Grip Arms.
54. Remove the transaxle support insulator through bolt and nut.
55. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
56. Remove the nut, bolt and engine mount brace.
57. Remove the 4 engine mount nuts.
58. Remove the 3 bolts and the engine mount.
59. Lower the engine and transaxle assembly from the vehicle.
60. Remove the 3 bolts and the accessory drive belt tensioner.
61. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
62. Using the 3 Jaw Puller, remove the crankshaft pulley.
63. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
64. Remove the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
65. Disconnect the 3 LH coil-on-plug electrical connectors.
66. Remove the 3 bolts and the 3 LH-coil-on-plugs.
67. Detach the wiring harness connector pin-type retainer from the LH valve cover.
68. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
69. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the wiring harness pin-type retainer.
70. Detach the 2 wiring harness pin-type retainers.
71. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. Detach the wiring harness connector pin-type retainer from the LH valve cover.
72. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
73. Detach the 2 wiring harness retainers and position the harness aside.
74. Loosen the 4 bolts and 7 stud bolts. Remove the LH valve cover. Discard the gasket.
75. Disconnect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Detach the wiring harness pin-type retainer.
76. Disconnect the EVAP vapor tube from the EVAP canister vent solenoid. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Detach the EVAP tube retainer.
77. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
78. Disconnect the crankcase ventilation hose from the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
79. Remove the upper intake manifold support bracket bolt.
80. Remove the 7 bolts and the upper intake manifold. Remove and discard the gasket. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
81. Disconnect the 3 RH coil-on-plug electrical connectors.
82. Remove the 3 bolts and the 3 RH-coil-on-plugs.
83. Disconnect the HO2S and CMS electrical connectors. Detach the 2 wiring harness retainers from the RH valve cover.
84. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the 2 wiring harness retainers.
85. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
86. Detach the wiring harness retainer.
87. Remove the 2 nuts and position aside the 2 power steering hose brackets.
88. Loosen the 3 bolts and 8 stud bolts. Remove the RH valve cover. Discard the gasket.
89. Inspect the VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
90. Inspect the spark plug tube seals. Remove any damaged seals. Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
91. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
92. Remove the 3 bolts and the power steering pump.
93. Remove the 26 front cover bolts.
94. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
95. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown in illustration.
96. Remove the 3 bolts and the LH valve train oil tube.
97. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
98. Remove the 3 bolts and the RH valve train oil tube.
99. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
100. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
101. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
102. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
103. Remove the 2 bolts and the primary timing chain tensioner.
104. Remove the primary timing chain tensioner arm.
105. Remove the 2 bolts and the lower LH primary timing chain guide.
106. Remove the bolt and the LH intake VCT oil control solenoid. 107.
107. Remove the bolt and the RH intake VCT oil control solenoid.
108. Remove the primary timing chain. LH camshafts
109. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
110. Remove and discard the 2 LH VCT assembly bolts.
111. Remove the 2 LH VCT assemblies and secondary timing chain. Remove the Secondary Chain Hold Down.
112. Remove the Camshaft Holding Tool from the LH camshafts.
113. Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts. RH camshafts
114. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
115. Remove and discard the 2 RH VCT assembly bolts.
116. Remove the 2 RH VCT assemblies and secondary timing chain. Remove the Secondary Chain Hold Down.
117. Remove the Camshaft Holding Tool from the RH camshafts.
118. Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.

Valve Tappets

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. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S03332497282012081400000) .
2. Remove the valve tappets from the cylinder head.

Valve Spring, Retainer and Seal

SPECIAL TOOLS CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249

Scheme 642

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.

Scheme 643

Scheme 644

1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to «VALVE TAPPETS»(ref-494555-S39868208182012081400000) .
2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
3. Pressurize the cylinder using compressed air.
4. Using the Valve Spring Compressors, remove the keys, retainer and spring.
5. Remove and discard the valve stem seal.

Cylinder Head - RH

MATERIAL SPECIFICATIONS

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, can cause engine failure.

Note. If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

Scheme 645

Scheme 646

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

1. Remove the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S03332497282012081400000) .
2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
3. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
4. Disconnect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
5. Remove the 2 bolts and the 2 CMP sensors.
6. Remove the bolt and the ground cable from the RH cylinder.
7. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
8. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
9. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
10. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
11. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
12. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
13. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
14. Remove and discard the 6 RH exhaust manifold studs.
15. Remove the bolt and the RH primary timing chain guide.
16. Remove the 2 bolts and the engine lifting eye.
17. Remove the bolt and the upper intake manifold bracket.
18. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
19. Remove the 2 thermostat housing-to-lower intake manifold bolts.
20. 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.
21. Disconnect and remove the CHT sensor jumper harness.
22. Remove the valve tappets from the cylinder head.
23. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
24. Remove and discard the M6 bolt.
25. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
26. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
27. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .

Cylinder Head - LH

MATERIAL SPECIFICATIONS

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, can cause engine failure.

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

1. Remove the LH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S03332497282012081400000) .
2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
3. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
4. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
5. Remove the 2 bolts and the 2 LH CMP sensors.
6. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
7. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector. Remove the wiring harness retainer from the rear of the LH cylinder head.
8. Disconnect the A/C compressor electrical connector.
9. Remove the nut and disconnect the generator B+ cable.
10. Disconnect the generator electrical connector.
11. Detach the wiring harness retainer from the generator.
12. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
13. Remove the nut, 2 bolts and the A/C compressor.
14. Remove the nut, bolt and the generator.
15. Remove the LH Heated Oxygen Sensor (HO2S).
16. Remove the 3 bolts and the LH exhaust heat shield.
17. Remove the 6 nuts and the LH catalytic converter. Discard the nuts and the gasket.
18. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust manifold cleaning and inspection in «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
19. Remove and discard the 6 LH exhaust manifold studs.
20. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
21. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
22. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
23. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
24. Remove the 2 thermostat housing-to-lower intake manifold bolts.
25. 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.
26. Remove the bolt and the upper LH primary timing chain guide.
27. Remove the valve tappets from the cylinder head.
28. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
29. Remove and discard the M6 bolt.
30. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
31. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
32. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .

SPECIAL TOOLS CHART 3 Jaw Puller 303-D121 or equivalent Handle 205-153 (T80T-4000-W) Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

MATERIAL SPECIFICATIONS

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, can cause engine failure.

Note. If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

Note. For additional information, refer to the exploded view under the ASSEMBLY service information.

All vehicles

Scheme 694

Scheme 695

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Scheme 699

Scheme 700

Scheme 701

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Scheme 706

Scheme 707

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Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

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Scheme 720

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Scheme 727

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Scheme 737

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Scheme 750

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Scheme 780

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Scheme 791

1. Remove the 8 bolts and the flexplate.
2. Remove the crankshaft sensor ring.
3. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
4. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
6. Remove the 3 bolts and the accessory drive belt tensioner.
7. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
8. Using the 3 Jaw Puller, remove the crankshaft pulley.
9. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
10. Remove the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
11. Disconnect the 3 LH coil-on-plug electrical connectors.
12. Detach the wiring harness connector pin-type retainer from the LH valve cover.
13. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
14. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the wiring harness pin-type retainer.
15. Detach the 2 wiring harness pin-type retainers.
16. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. Detach the wiring harness connector pin-type retainer from the LH valve cover.
17. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
18. Detach the 2 wiring harness retainers and position the harness aside.
19. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
20. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector. Remove the wiring harness retainer from the rear of the LH cylinder head.
21. Detach the wiring harness retainer from the intake manifold.
22. Disconnect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Detach the wiring harness pin-type retainer.
23. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
24. Disconnect the crankcase ventilation hose from the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
25. Remove the upper intake manifold support bracket bolt.
26. Remove the 7 bolts and the upper intake manifold. Remove and discard the gasket. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
27. Disconnect the 3 RH coil-on-plug electrical connectors.
28. Disconnect the HO2S and CMS electrical connectors. Detach the 2 wiring harness retainers from the RH valve cover.
29. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the 2 wiring harness retainers.
30. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
31. Detach the wiring harness retainer.
32. Disconnect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
33. Disconnect the Knock Sensor (KS) electrical connector.
34. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
35. Remove the bolt and the ground cable from the RH cylinder.
36. Remove the nut, the bolt and the heat shield.
37. Remove the wiring harness retainer stud bolt.
38. Remove the wiring harness grommet.
39. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
40. Disconnect the A/C compressor electrical connector.
41. Remove the nut and disconnect the generator B+ cable.
42. Disconnect the generator electrical connector.
43. Detach the wiring harness retainer from the generator.
44. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
45. Remove the nut, 2 bolts and the A/C compressor.
46. Remove the A/C compressor mounting stud from the oil pan.
47. Remove the nut, bolt and the generator.
48. Remove the 2 nuts and position aside the 2 power steering hose brackets.
49. Remove the 3 bolts and the power steering pump.
50. Remove the LH Heated Oxygen Sensor (HO2S).
51. Remove the 3 bolts and the LH exhaust heat shield.
52. Remove the 6 nuts and the LH catalytic converter. Discard the nuts and the gasket.
53. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust manifold cleaning and inspection in «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
54. Remove and discard the 6 LH exhaust manifold studs. Front Wheel Drive (FWD) vehicles
55. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket. All vehicles
56. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
57. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
58. Remove and discard the 6 RH exhaust manifold studs.
59. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
60. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
61. Remove the pin-type retainer and the cover.
62. Remove the 2 bolts and the 2 LH CMP sensors.
63. Remove the 2 bolts and the 2 RH CMP sensors.
64. Remove the 2 thermostat housing-to-lower intake manifold bolts.
65. 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.
66. Remove the coolant inlet tube and thermostat assembly. Remove and discard the O-ring seal.
67. Disconnect and remove the CHT sensor jumper harness.
68. Remove the bolt and the CKP sensor.
69. Remove the EOP switch.
70. Remove the 3 bolts and the oil filter adapter. Discard the gasket.
71. Remove the 3 bolts and the 3 LH-coil-on-plugs.
72. Loosen the 4 bolts and 7 stud bolts. Remove the LH valve cover. Discard the gasket.
73. Remove the 3 bolts and the 3 RH-coil-on-plugs.
74. Loosen the 3 bolts and 8 stud bolts. Remove the RH valve cover. Discard the gasket.
75. Inspect the VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
76. Inspect the spark plug tube seals. Remove any damaged seals. Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
77. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
78. Remove the 26 front cover bolts.
79. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
80. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown in illustration.
81. Remove the 3 bolts and the LH valve train oil tube.
82. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
83. Remove the 3 bolts and the RH valve train oil tube.
84. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
85. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
86. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
87. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
88. Remove the 2 bolts and the primary timing chain tensioner.
89. Remove the primary timing chain tensioner arm.
90. Remove the 2 bolts and the lower LH primary timing chain guide.
91. Remove the bolt and the LH intake VCT oil control solenoid.
92. Remove the bolt and the RH intake VCT oil control solenoid.
93. Remove the primary timing chain.
94. Remove the bolt and the upper LH primary timing chain guide.
95. Remove the crankshaft timing chain sprocket.
96. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
97. Remove and discard the 2 LH VCT assembly bolts.
98. Remove the 2 LH VCT assemblies and secondary timing chain. Remove the Secondary Chain Hold Down.
99. Remove the Camshaft Holding Tool from the LH camshafts.
100. Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.
101. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
102. Remove and discard the 2 RH VCT assembly bolts.
103. Remove the 2 RH VCT assemblies and secondary timing chain. Remove the Secondary Chain Hold Down.
104. Remove the bolt and the RH primary timing chain guide.
105. Remove the Camshaft Holding Tool from the RH camshafts.
106. Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.
107. Remove the 2 bolts and the engine lifting eye.
108. Remove the bolt and the upper intake manifold bracket.
109. Remove the valve tappets from the cylinder heads.
110. Remove and discard the M6 bolt from each cylinder head.
111. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
112. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
113. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
114. Remove the 2 bolts and the KS.
115. Remove the 8 bolts and the coolant pump.
116. Remove the 16 oil pan bolts.
117. Using a suitable pry tool, locate the 5 pry pads shown in illustration and pry the oil pan loose and remove.
118. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
119. Remove the 3 bolts and the oil pump.
120. Remove the 8 crankshaft rear seal retainer bolts.
121. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
122. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2 inch, white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm. Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
123. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
124. Remove the bolts in the sequence shown in illustration. Remove the main bearing cap support brace. Discard the bolts.
125. Remove the connecting rod cap bolts and cap.
126. Remove the piston/rod assembly from the engine block.
127. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
128. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration. Discard the bolts.
129. Remove the 4 main bearing caps.
130. Remove the crankshaft.
131. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
132. Remove the 4 crankshaft main bearings from the cylinder block.
133. Remove the 4 crankshaft main bearings from the main bearing caps.
134. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
135. Clean the sealing surfaces of the cylinder block 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.

Cylinder Head

SPECIAL TOOLS CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 792

MATERIAL SPECIFICATIONS

Scheme 793

Piston

MATERIAL SPECIFICATIONS

Scheme 794

SPECIAL TOOLS CHART Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Hold Down, Secondary Chain 303-1530 Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Front Crankshaft Seal 303-1251 Installer, VCT Spark Plug Tube Seal 303-1247/2 Powertrain Lift 300-OTC1585AE Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

MATERIAL SPECIFICATIONS

RH camshafts

Scheme 802

Scheme 803

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Scheme 806

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Scheme 906

1. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
2. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
3. Position the 4 camshaft seals gaps as shown in illustration.
4. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
5. Loosen the 4 camshaft caps bolts.
6. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
7. 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-494555-S00964058092012081400000) .
8. Remove the 3 bolts and the RH valve train oil tube.
9. Rotate the RH camshafts to the TDC position as shown in illustration.
10. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
11. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
12. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
13. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
14. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
15. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides. LH camshafts
16. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
17. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
18. Position the 4 camshaft seals gaps as shown in illustration.
19. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
20. Loosen the 4 camshaft caps bolts.
21. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
22. 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-494555-S00964058092012081400000) .
23. Remove the 3 bolts and the LH valve train oil tube.
24. Rotate the LH camshafts to the TDC position as shown in illustration.
25. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
26. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
27. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
28. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
29. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
30. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides. All camshafts
31. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
32. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
33. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
34. Install the primary timing chain tensioner arm.
35. Reset the primary timing chain tensioner. Release the ratchet detent. Using a soft-jawed vise, compress the ratchet plunger. Align the hole in the ratchet plunger with the hole in the tensioner housing. Install a suitable lockpin.
36. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
37. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
38. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
39. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
40. Remove the RH Camshaft Holding Tool.
41. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
42. Remove the LH Camshaft Holding Tool.
43. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
44. 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.
45. 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.
46. Install the Alignment Pins.
47. 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 4 inner bolt 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.
48. Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22. Tighten in sequence to 3 Nm (27 lb-in).
49. Remove the Alignment Pins.
50. Install the M6 engine front cover bolt.
51. Install the 3 M10 engine front cover bolts.
52. 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 7 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in). Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in). Stage 4: Loosen bolt 26 one full turn. Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees. Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees. Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.
53. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
54. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
55. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
56. 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.
57. Using a new gasket, install the RH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
58. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
59. Position the 2 power steering hose brackets and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
60. Attach the wiring harness retainer.
61. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
62. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 2 wiring harness retainers.
63. Connect the HO2S and CMS electrical connectors. Attach the 2 wiring harness retainers to the RH valve cover.
64. Install the 3 RH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in).
65. Connect the 3 RH coil-on-plug electrical connectors.
66. Using a new gasket, install the intake manifold and the 7 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
67. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
68. Connect the crankcase ventilation hose to the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
69. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
70. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Attach the pin-type retainer.
71. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Attach the wiring harness pin-type retainer.
72. 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.
73. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
74. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
75. Attach the 2 wiring harness retainers.
76. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
77. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector. Attach the wiring harness connector pin-type retainer to the LH valve cover.
78. Attach the 2 wiring harness pin-type retainers.
79. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the wiring harness pin-type retainer.
80. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
81. Attach the wiring harness connector pin-type retainer to the LH valve cover.
82. Install the 3 LH-coil-on-plugs and the 3 bolts. Tighten to 7 Nm (62 lb-in.
83. Connect the 3 LH coil-on-plug electrical connectors.
84. Install the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
85. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
86. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
87. 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.
88. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
89. Raise the engine and transaxle assembly into the vehicle.
90. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
91. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
92. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (177 lb-in).
93. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten the bolt to 80 Nm (59 lb-ft). Tighten the 3 nuts to 63 Nm (46 lb-ft).
94. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
95. Connect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
96. Using the Powertrain Lift, raise the subframe into the installed position.
97. Install the 2 middle subframe nuts. Tighten to 133 Nm (98 lb-ft).
98. Install the 2 front subframe nuts. Tighten to 133 Nm (98 lb-ft).
99. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
100. Position the subframe brace and loosely install the 2 bolts.
101. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
102. Tighten the 4 bolts to 90 Nm (66 lb-ft).
103. Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 9 Nm (80 lb-in).
104. Install the 3 RH lower bumper-to-subframe nuts. Tighten to 9 Nm (80 lb-in).
105. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
106. Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
107. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube. Tighten to 48 Nm (35 lb-ft).
108. Install the engine roll restrictor-to-subframe through bolt. Tighten to 115 Nm (85 lb-ft).
109. Install the roll restrictor heat shield and the 2 nuts. Tighten to 9 Nm (80 lb-in). AWD vehicles
110. 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. Tighten to 70 Nm (52 lb-ft). All vehicles
111. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 9 Nm (80 lb-in).
112. Connect the power steering cooler hose.
113. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
114. Connect the 2 transmission fluid cooler tubes.
115. Install the 2 secondary latches onto the transmission fluid cooler tubes.
116. Install the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-494576) .
117. Install the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
118. Install the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
119. Install the ground wire and bolt to the engine front cover. Tighten to 10 Nm (89 lb-in).
120. Install the oil level indicator.
121. Connect the wiring harness electrical connector. Attach the wiring harness retainer to the RH valve cover stud bolt.
122. Connect the 2 PCM electrical connectors. Attach the 3 wiring harness retainers.
123. Connect the hose to the power steering reservoir.
124. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
125. Using a new O-ring seal, connect the A/C tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
126. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
127. Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
128. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
129. Connect the vacuum hose to the upper intake manifold.
130. Attach the 3 wiring harness retainers to the bracket and inner fender.
131. Connect the wiring harness electrical connector.
132. Attach the 2 wiring harness retainers to the stud bolt and bracket.
133. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in). Connect the wiring harness electrical connector.
134. Connect the power feed to the battery terminal and install the 2 nuts. Tighten to 8 Nm (71 lb-in). Connect the wiring harness electrical connector.
135. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
136. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
137. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
138. Install the intermediate shaft and the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
139. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
140. Fill the engine with clean engine oil.
141. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
142. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-494570) .
143. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
144. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

MATERIAL SPECIFICATIONS

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. Install the valve tappets.
2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S11409700892012081400000) .

SPECIAL TOOLS CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 907

Scheme 908

Scheme 909

MATERIAL SPECIFICATIONS

Scheme 910

1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-494555-S26200713572012081400000) .

MATERIAL SPECIFICATIONS

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, can cause engine failure.

Note. If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

Note. The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

Scheme 911

Scheme 912

Scheme 913

Scheme 914

Scheme 915

Scheme 916

Scheme 917

Scheme 918

Scheme 919

Scheme 920

Scheme 921

Scheme 922

Scheme 923

Scheme 924

Scheme 925

Scheme 926

Scheme 927

Scheme 928

Scheme 929

Scheme 930

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees Stage 5: Tighten 45 degrees.
2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets.
4. Install and connect the CHT sensor jumper harness.
5. 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).
6. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
7. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
8. Install the upper intake manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
9. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
10. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
11. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
12. 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).
13. If equipped, install the block heater wiring harness onto the engine. Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees. Tighten the block heater to 40 Nm (30 lb-ft).
14. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
15. Install the LH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
16. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
17. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
18. Install the ground wire and the bolt on the RH cylinder. Tighten to 10 Nm (89 lb-in).
19. Install the 2 CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Connect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
21. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
22. If equipped, position the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
23. Install the RH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S11409700892012081400000) .

MATERIAL SPECIFICATIONS

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, can cause engine failure.

Note. If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

Note. The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

Scheme 931

Scheme 932

Scheme 933

Scheme 934

Scheme 935

Scheme 936

Scheme 937

Scheme 938

Scheme 939

Scheme 940

Scheme 941

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

Scheme 955

1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees Stage 5: Tighten 45 degrees.
2. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets.
4. Install the LH upper primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
5. 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).
6. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
7. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
8. If equipped, install the block heater wiring harness onto the engine. Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees. Tighten the block heater to 40 Nm (30 lb-ft).
9. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
10. Install the LH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
11. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
12. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts. Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft). Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
13. Install the LH exhaust heat shield and the 3 bolts. Tighten to 12 Nm (106 lb-in).
14. Install the LH HO2S. Tighten to 48 Nm (35 lb-ft).
15. Install the generator, the bolt and the nut. Tighten to 47 Nm (35 lb-ft).
16. Install the A/C compressor, the 2 bolts and the nut. Tighten to 25 Nm (18 lb-ft).
17. Connect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
18. Attach the wiring harness retainer to the generator.
19. Connect the generator electrical connector.
20. Connect the generator B+ cable and install the nut. Tighten to 7 Nm (150 lb-in).
21. Connect the A/C compressor electrical connector.
22. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector. Install the wiring harness retainer to the rear of the LH cylinder head.
23. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
24. Install the 2 LH CMP sensors and the 2 bolts. Tighten to 10 Nm (89 lb-in).
25. Connect the 2 LH CMP sensors electrical connectors.
26. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
27. If equipped, position the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
28. Install the LH camshafts. For additional information, refer to «CAMSHAFT»(ref-494555-S11409700892012081400000) .