Engine Mechanical - 3.0L (4V): Removal & Installation Mazda Tribute I рестайлинг

Installation

Scheme 164

1. Install the water pump belt on the water pump pulley and position it on the camshaft pulley.
2. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
3. Install the coolant pump belt shield and install the coolant pump belt shield bolts.

Scheme 165

1. With the vehicle in NEUTRAL, position it on a hoist. .
2. Remove the splash shield.
3. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - 3.0L (4V)»(ref-221817-S07836805682006022600000) .
4. Remove the bolt and the accessory drive belt tensioner.
5. To install, reverse the removal procedure.

Scheme 166

1. Remove the LH ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG AND SPARK PLUG -- 3.0L (4V)»(ref-221836-S25109414582006022600000) .
2. Remove the coolant pump belt shield nuts and the coolant pump belt shield.
3. Disconnect the wiring retainers.
4. Disconnect the wiring retainers.
5. Remove the valve cover bolts.
6. Remove the valve cover stud bolts and the valve cover.
7. Remove the valve cover gasket.

Scheme 167

1. Clean the valve cover, cylinder head and front cover sealing surfaces with metal surface cleaner.
2. Apply a 5mm (0.20 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Install the valve cover gasket.
4. Install valve cover.
5. Install the valve cover stud bolts.
6. Install the valve cover bolts.
7. Position the valve cover and tighten the stud bolts and bolts in the sequence shown.
8. Reconnect the wiring retainers.
9. Reconnect the wiring retainers.
10. Install the LH ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG AND SPARK PLUG -- 3.0L (4V)»(ref-221836-S25109414582006022600000) .

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1. Remove the upper intake manifold. See «UPPER INTAKE MANIFOLD»(ref-221824-S38983032742006022600000) .
2. Remove the RH ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG AND SPARK PLUG -- 3.0L (4V)»(ref-221836-S25109414582006022600000) .
3. Disconnect the positive crankcase ventilation (PCV) valve electrical connector.
4. Remove the PCV tube.
5. Disconnect the radio ignition interference capacitor and detach the retainers from the stud bolts.
6. Remove the nut and the radio ignition interference capacitor.
7. Remove the nuts and position the engine control harness aside.
8. Remove the valve cover stud bolts and the valve cover.

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1. Clean the valve cover, cylinder head and front cover sealing surfaces with metal surface cleaner.
2. Install the valve cover gasket. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within four minutes of sealant application. Apply a 5mm (0.20 in) dot of silicone gasket sealant to the front cover to cylinder head joints.
3. Position the valve cover, install the nuts and tighten the stud bolts in the sequence shown.
4. Install the engine control harness and the nuts.
5. Install the radio ignition interference capacitor and the nut.
6. Position back the engine control harness and install the nuts.
7. Install the PCV tube.
8. Attach the positive crankcase ventilation (PCV) valve electrical connector.
9. Install the upper intake manifold. See «UPPER INTAKE MANIFOLD»(ref-221824-S38983032742006022600000) .
10. Remove the RH ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG AND SPARK PLUG -- 3.0L (4V)»(ref-221836-S25109414582006022600000) .

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1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the splash shield.
3. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - 3.0L (4V)»(ref-221817-S07836805682006022600000) .
4. Use the special tool to hold the crankshaft pulley and remove the crankshaft pulley bolt and washer.
5. Use the special tool to remove crankshaft pulley.

Note. Apply silicone gasket and sealant to the key-way in the crankshaft pulley.

Note. Install the crankshaft pulley within four minutes of applying silicone gasket and sealant to the Woodruff key slot.

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Scheme 182

1. Using the special tool, install the crankshaft pulley.
2. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in four stages: Stage 1: Tighten the bolt to 120 N.m (89 ft-lbf). Stage 2: Loosen the bolt one full turn. Stage 3: Tighten the bolt to 50 N.m (37 ft-lbf). Stage 4: Tighten the bolt an additional 90 degrees.
3. Install the accessory drive belt. See «ACCESSORY DRIVE BELT - 3.0L (4V)»(ref-221817-S07836805682006022600000) .
4. Install the splash shield.

Scheme 183

1. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - 3.0L (4V)»(ref-221817-S07836805682006022600000) .
2. Remove the crank shaft pulley. See «CRANKSHAFT PULLEY»(ref-221817-S39545615222006022600000) .
3. Remove the front cover seal with the special tool.

Scheme 184

1. Lubricate the front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal.
3. Install the crank shaft pulley. See «CRANKSHAFT PULLEY»(ref-221817-S39545615222006022600000) .
4. Install the accessory drive belt. See «ACCESSORY DRIVE BELT - 3.0L (4V)»(ref-221817-S07836805682006022600000) .

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1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the transaxle. See «TRANSAXLE -- 3.0L (4V)»(ref-221909-S40912444072006022600000) .
3. Remove the flexplate bolts and the flexplate.
4. Using the special tools, remove the crankshaft rear oil seal.

Note. Clean all sealing surfaces with metal surface cleaner.

Note. Lubricate the crankshaft rear oil lips with clean engine oil.

Scheme 187

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate and the flexplate bolts.
3. Install the transaxle. See «TRANSAXLE -- 3.0L (4V)»(ref-221909-S40912444072006022600000) .

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1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the negative battery cable. See «BATTERY DISCONNECT»(ref-221834-S42533501902006022600000) .
3. Remove the oil pan. See «OIL PAN»(ref-221819-S20861082012006022600000) .
4. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-221817-S39545615222006022600000) .
5. Remove the generator. See «GENERATOR»(ref-221834-S25486512672006022600000) .
6. Remove the RH and LH valve covers. See «VALVE COVER - LH»(ref-221817-S41584461092006022600000) and «VALVE COVER - RH»(ref-221817-S20945219832006022600000) .
7. Remove the engine support insulator. See «ENGINE SUPPORT INSULATORS - FRONT, RH»(ref-221817-S16964552182006022600000) .
8. Remove the accessory drive belt tensioner bolt and the accessory drive belt tensioner.
9. Remove the accessory drive belt idler pulley bolt and the accessory drive belt idler pulley.
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Disconnect the camshaft position (CMP) sensor electrical connector.
12. To gain access to the power steering pump bolts, remove the nut and the power steering pump pulley.
13. Remove the power steering pump bolts and position power steering pump aside.
14. Remove the engine front cover bolts.
15. Remove the engine front cover bolts.
16. Remove the engine front cover bolts.
17. Remove the engine front cover stud bolts and the engine front cover.
18. Remove the engine front cover gasket.
19. To access the CKP sensor electrical connector, remove the nut and position the heated oxygen sensor electrical connector bracket aside.

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1. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface cleaner.
2. Install the gasket.
3. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block and cylinder head mating surfaces.
4. Position the engine front cover, install the engine front cover, bolts and tighten the bolts in the sequence shown.
5. Install the oil pan. See «OIL PAN»(ref-221819-S20861082012006022600000) .
6. Position back the CKP sensor, install the heated oxygen sensor electrical connector bracket and nut and connect the electrical connector.
7. Install the engine front cover bolts.
8. Install the engine front cover bolts.
9. Position back the power steering pump and install the power steering pump bolts.
10. Install the power steering pump pulley.
11. Install the generator. See «GENERATOR»(ref-221834-S25486512672006022600000) .
12. Install the crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-221817-S39545615222006022600000) .
13. Connect the camshaft position (CMP) sensor electrical connector.
14. Install the accessory drive belt idler pulley and the accessory drive belt idler pulley bolt.
15. Install the accessory drive belt tensioner and the accessory drive belt tensioner bolt.
16. Install the engine support insulator. See «ENGINE SUPPORT INSULATORS - FRONT, RH»(ref-221817-S16964552182006022600000) .
17. Install the RH and LH valve covers. See «VALVE COVER - LH»(ref-221817-S41584461092006022600000) and «VALVE COVER - RH»(ref-221817-S20945219832006022600000) .
18. Connect the negative battery cable. See «BATTERY DISCONNECT»(ref-221834-S42533501902006022600000) .

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1. Remove the engine front cover. See «ENGINE FRONT COVER»(ref-221817-S42617341092006022600000) .
2. Remove the ignition pulse wheel.
3. Install the damper bolt.
4. Remove the LH and RH spark plugs.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and re-check.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
10. Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify that the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the LH timing chain and timing chain guide.
14. Remove the damper bolt and the crankshaft sprockets.

Note. Install the sprockets with the timing marks out.

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1. Install the crankshaft sprockets.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston With a 1.5 mm (0.06 in) wire or paper clip.
6. If timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to 42 and mark the link.
7. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
8. Install the LH timing chain and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolt.
9. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. Position the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
12. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
15. Verify the timing with the following steps. There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and crankshaft timing marks. There should be 30 chain links between the camshaft and crankshaft timing marks.
16. Remove the crankshaft damper bolt.
17. Install the ignition pulse wheel.
18. Install the LH and RH spark plugs.
19. Install the engine front cover. See «ENGINE FRONT COVER»(ref-221817-S42617341092006022600000) .

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1. Remove the water pump belt. See «WATER PUMP BELT - 3.0L (4V)»(ref-221817-S38649550912006022600000) .
2. Using the special tools remove the water pump drive pulley.
3. Remove the timing drive components. See «TIMING DRIVE COMPONENTS»(ref-221817-S16594218282006022600000) .
4. Using the special tools, remove the camshaft oil seal and discard.
5. Remove the bolts, the intake camshaft oil seal retainer and discard the press-in-place gasket.
6. Loosen the LH camshaft cap bolts evenly in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
7. Remove the camshafts.

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Scheme 221

1. Lubricate camshafts with SAE 5W-30 motor oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with SAE 5W-30 motor oil. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with SAE 5W-30 motor oil. Install the bearing thrust caps and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Install a new press-in-place gasket and install the camshaft oil seal retainer. Install a new gasket.
6. Install the timing drive components. See «TIMING DRIVE COMPONENTS»(ref-221817-S16594218282006022600000) .
7. Install the new camshaft oil seal. Using special tools positioned over the oil seal, turn to install to the seal.
8. Using special tool, install the water pump drive pulley.
9. Install the water pump belt. See «WATER PUMP BELT - 3.0L (4V)»(ref-221817-S38649550912006022600000) .

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Scheme 223

1. Remove the timing drive components. See «TIMING DRIVE COMPONENTS»(ref-221817-S16594218282006022600000) .
2. Loosen the RH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
3. Remove the camshafts.

Note. Be sure camshaft bearing caps are installed in the original positions.

Scheme 224

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Scheme 226

1. Lubricate camshafts with SAE 5W-30 motor oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with SAE 5W-30 motor oil and install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with SAE 5W-30 motor oil. Install the bearing thrust caps and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Install the tinning drive components. See «TIMING DRIVE COMPONENTS»(ref-221817-S16594218282006022600000) .

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Scheme 229

1. Remove the LH and RH valve covers. See «VALVE COVER - RH»(ref-221817-S20945219832006022600000) and «VALVE COVER - LH»(ref-221817-S41584461092006022600000) .
2. Remove the LH and RH spark plugs.
3. Remove the RH front wheel. See «WHEELS AND TIRES»(ref-221854) .
4. Remove the splash shield.
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower.
6. Using the special tool, remove the followers.
7. To install, reverse the removal procedure. Lubricate the camshaft followers with SAE 5W-20 Motor Oil.

Scheme 230

1. Remove the roller followers. See «ROLLER FOLLOWERS»(ref-221817-S12513556632006022600000) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer, and valve spring.
4. To install, reverse the removal procedure.

Scheme 231

1. Remove the camshaft followers. See «ROLLER FOLLOWERS»(ref-221817-S12513556632006022600000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with SAE 5W-20 Motor Oil.

Removal

1. Remove the valve spring. See «VALVE SPRING»(ref-221817-S25721576072006022600000) .
2. Remove the valve seal.

1. Using the special tool, install the valve seal.
2. Install the valve spring. See «VALVE SPRING»(ref-221817-S25721576072006022600000) .

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Scheme 233

1. Remove the lower intake manifold. See «LOWER INTAKE MANIFOLD»(ref-221824-S05121062672006022600000) .
2. Remove the coolant bypass tube. See «BYPASS TUBE -- 3.0L (4V)»(ref-221821-S02059940552006022600000) .
3. Remove the LH camshafts. See «CAMSHAFTS - LH»(ref-221817-S11550761802006022600000) .
4. Remove the camshaft followers.
5. Remove the hydraulic lash adjusters.
6. Position the water pump and housing aside. See «WATER PUMP -- 3.0L (4V)»(ref-221821-S17579794822006022600000) .
7. Raise the vehicle.
8. Remove the LH exhaust manifold. See «EXHAUST MANIFOLD -- LH»(ref-221829-S24228497482006022600000) .
9. Remove the oil level indicator tube nut.
10. Lower the vehicle.
11. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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1. Position the LH cylinder head, gasket and install the bolts in the sequence shown. Tighten the bolts in six stages. Stage 1: Tighten to 40 Nm (30 ft-lbf). Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 ft-lbf). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Install the water pump. See «WATER PUMP -- 3.0L (4V)»(ref-221821-S17579794822006022600000) .
3. Raise the vehicle.
4. Install the LH exhaust manifold. See «EXHAUST MANIFOLD -- LH»(ref-221829-S24228497482006022600000) .
5. Install the oil level indicator tube nut.
6. Lower the vehicle.
7. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with SAE 5W-20 motor oil.
8. Install the camshaft followers. Lubricate the camshaft followers with SAE 5W-20 motor oil.
9. Install the LH camshafts. See «CAMSHAFTS - LH»(ref-221817-S11550761802006022600000) .
10. Install the coolant bypass tube. See «BYPASS TUBE -- 3.0L (4V)»(ref-221821-S02059940552006022600000) .
11. Install the lower intake manifold. See «LOWER INTAKE MANIFOLD»(ref-221824-S05121062672006022600000) .

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1. Remove the lower intake manifold. See «LOWER INTAKE MANIFOLD»(ref-221824-S05121062672006022600000) .
2. Remove the coolant bypass tube. See «BYPASS TUBE -- 3.0L (4V)»(ref-221821-S02059940552006022600000) .
3. Remove the exhaust gas recirculation (EGR) tube. See «EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 3.0L (4V)»(ref-221831-S13812988852006022600000) .
4. Remove the RH camshafts. See «CAMSHAFTS - RH»(ref-221817-S27570751032006022600000) .
5. Remove the camshaft followers.
6. Remove the hydraulic lash adjusters.
7. Raise the vehicle.
8. Remove the six nuts from the RH exhaust manifold.
9. Lower the vehicle.
10. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.

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Scheme 241

1. Position the RH cylinder head, gasket and install the bolts in the sequence shown. Tighten the bolts in six stages. Stage 1: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 2: Tighten bolts 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
2. Raise the vehicle.
3. Install RH exhaust manifold nuts in the sequence shown.
4. Lower the vehicle.
5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with SAE 5W-20 motor oil.
6. Install the camshaft followers. Lubricate the camshaft followers with SAE 5W-20 motor oil.
7. Install the RH camshafts. See «CAMSHAFTS - RH»(ref-221817-S27570751032006022600000) .
8. Install the coolant bypass tube. See «BYPASS TUBE -- 3.0L (4V)»(ref-221821-S02059940552006022600000) .
9. Install the exhaust gas recirculation (EGR) tube. See «EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 3.0L (4V)»(ref-221831-S13812988852006022600000) .
10. Install the lower intake manifold. See «LOWER INTAKE MANIFOLD»(ref-221824-S05121062672006022600000) .

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1. Remove the engine ground wire.
2. Using the special tools, support the engine.
3. Remove the A/C line bracket bolt and position the A/C lines out of the way.
4. Remove the engine support insulator bolt.
5. Remove the engine support tool. Remove the nut. Remove the bolts and insulator.
6. To install, reverse the removal procedure.

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1. Remove the battery tray. See «BATTERY TRAY -- 3.0L (4V)»(ref-221834-S22239518422006022600000) .
2. Remove the air cleaner outlet tube and air cleaner. See «AIR CLEANER OUTLET PIPE -- 3.0L (4V)»(ref-221824-S25313461482006022600000) .
3. Discharge and recover the refrigerant. See «DISCHARGING AND RECOVERY»(ref-221929-S14252176892006022600000) .
4. Raise and support the vehicle.
5. Remove the lower radiator air deflectors.
6. Drain the engine cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-221821-S22848327452006022600000) .
7. Drain the engine oil. Install a new drain plug gasket and tighten the drain plug.
8. Lower the vehicle.
9. Disconnect the fuel line. See «FUEL SYSTEM PRESSURE RELEASE»(ref-221826-S07207088302006022600000) .
10. Remove the water pump drive belt.
11. Disconnect the accelerator cable and if equipped cruise control actuator cable.
12. Disconnect the vapor management valve (VMV).
13. Disconnect the powertrain control module.
14. Disconnect the ground wire.
15. Disconnect the hoses.
16. Remove the tie-strap and position the hose out of the way.
17. Disconnect the connector from the power distribution box.
18. Remove the power distribution box cover.
19. Remove the nuts and the cables.
20. Disconnect the transaxle linkage.
21. Disconnect the brake booster vacuum hose.
22. Disconnect the vacuum line.
23. Disconnect the power steering return line.
24. Disconnect the power steering line. Disconnect the power steering pressure (PSP) switch electrical connector. Remove the bracket bolt. Disconnect the power steering line.
25. Remove the oil level indicator.
26. Disconnect the ground strap and the connector.
27. Remove the harness retainers and position the harness out of the way.
28. Remove the exhaust flexible pipe. See «EXHAUST FLEXIBLE PIPE -- 3.0L (4V)»(ref-221829-S34988247892006022600000) .
29. Remove the A/C compressor. See «AIR CONDITIONING (A/C) COMPRESSOR -- 3.0L (4V)»(ref-221930-S29186547602006022600000) .
30. Remove both front wheel and tire assemblies.
31. If equipped, remove the intermediate drive shaft. See «INTERMEDIATE SHAFT»(ref-221881-S20838121272006022600000) .
32. Separate the LH and RH sway bar links from the strut mount.
33. Remove the bolt and position aside the LH and RH wheel speed sensors if equipped.
34. If equipped, remove the LH and RH wheel speed sensor brackets.
35. Remove the LH and RH brake calipers from the steering knuckles and support them to the struts.
36. Remove the bolt and separate the struts from the LH and RH steering knuckles.
37. Remove the bolt and separate the steering shaft from the rack.
38. Disconnect the two transaxle cooler lines.
39. Remove the torque converter inspection cover.
40. Remove the four torque converter nuts.
41. Remove the four bolts.
42. If equipped disconnect the block heater wiring.
43. Position the universal powertrain lift.
44. Using a bracket from the heavy duty engine stand, support the front of the engine.
45. Remove the bolts and the nuts, remove the engine support bracket.
46. Disconnect the power steering return hose.
47. Remove the bolts and the transaxle support.
48. Remove two rear subframe bolts.
49. Remove the two subframe side nuts.
50. Remove the two bolts from the motor mount support.
51. Remove the powertrain from the vehicle.
52. Disconnect the heated oxygen sensors.
53. Disconnect the TR sensor.
54. Disconnect the transaxle harness electronic control switch.
55. Remove the bolt and separate the transaxle control harness from the bracket.
56. Remove the two bolts, the starter and harness as an assembly.
57. Disconnect the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor electrical connectors.
58. Disconnect the HO2S and the EGR tube from the exhaust manifold.
59. Disconnect the DPFE hoses and remove the EGR tube from the EGR valve.
60. Remove the generator. Disconnect the electrical connector. Remove the bolts.
61. Remove the six RH exhaust manifold nuts and gasket.
62. Remove the bolts and position the halfshaft support bracket out of the way.
63. Using the special tools, remove the powertrain from the universal powertrain lift.
64. Remove the six transaxle bolts.
65. Using the special tools, remove the engine from the transaxle and mount on a suitable engine stand.

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Scheme 357

1. Separate the engine control sensor wiring connectors from the upper intake manifold.
2. Disconnect the idle air control valve and the throttle position sensor.
3. Disconnect the exhaust gas regulation (EGR) vacuum regulator and the differential pressure feedback EGR electrical connectors.
4. Remove the positive crankcase ventilation (PCV) tube.
5. Disconnect the vacuum line from the fuel pressure regulator.
6. Disconnect and remove the engine control wire harness.
7. Remove the bolts and upper intake manifold.
8. Disconnect the crankshaft and camshaft position sensors.
9. Disconnect the radio ignition interference capacitor.
10. Disconnect the remaining electrical connectors and harness retainers and remove the harness. coils-on-plugs fuel injectors
11. Remove the bolts and the six coil-on-plugs.
12. Disconnect the coolant temperature sensor and the oil pressure switch.
13. Remove the fuel charging wire harness.
14. Remove the lower intake manifold.
15. Remove the radio interference capacitor. Remove the nut.
16. Remove the RH valve cover. Remove and discard the gasket if damaged.
17. Remove the engine lift bracket.
18. Remove the LH exhaust manifold. Remove and discard the gasket if damaged.
19. Remove the RH exhaust manifold. Remove and discard the gasket if damaged.
20. Remove the water pump belt cover.
21. Remove the LH valve cover. Remove and discard the gasket if damaged. Vehicles equipped with water pump belt tensioner
22. Rotate the belt tensioner clockwise and remove the water pump belt. Vehicles equipped with water pump belt tensioner
23. Cut and remove the water pump belt. Discard the belt. Vehicles not equipped with water pump belt tensioner
24. Disconnect the hoses.
25. Remove the water pump assembly.
26. Disconnect the coolant hoses at the oil cooler.
27. Remove the bolt.
28. Using the special tool, remove the crankshaft damper.
29. Remove the power steering pump pulley.
30. Remove the oil filter.
31. Remove the power steering pump.
32. Remove the generator support bracket.
33. Remove the oil cooler.
34. Remove the oil pressure sender and the block heater.
35. Remove the bolts and studs and the oil pan. Discard the gasket.
36. Remove the bolts, nut and the oil pick up tube and screen.
37. Remove the nuts and the oil pan baffle.
38. Remove the stud and the oil level indicator and tube.
39. Remove the bolts, studs, and the front cover. Discard the gasket.
40. Remove the crankshaft front seal from the front cover.
41. Remove the ignition pulse wheel.
42. Install the damper bolt.
43. Remove the LH and RH spark plugs.
44. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and re-check.
45. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
46. Verify that the RH camshafts are correctly positioned.
47. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
48. Remove the bolts, RH timing chain guide and the timing chain.
49. Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
50. Verify that the LH camshafts are in the neutral position.
51. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
52. Remove the LH timing chain and timing chain guide.
53. Remove the damper bolt and the crankshaft sprockets.
54. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
55. Remove the LH and RH camshafts.
56. Remove the LH and RH camshaft followers. Mark the location of the followers using a permanent-type marker.
57. Remove the coolant bypass tube.
58. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the gaskets.
59. Remove the power steering/engine support bracket.
60. Remove the oil separator.
61. Remove the bolts in the indicated sequence and remove the oil pump.
62. Using the special tool, remove the cylinder ridge.
63. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
64. Using the special tool, remove the piston/rod assembly from the engine block.
65. Remove the engine block from the stand and place it on a workbench.
66. Remove the bolts and the flexplate.
67. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
68. Remove the crankshaft rear main seal and remove the crankshaft.
69. Remove the crankshaft key.
70. Remove the crankshaft thrust bearing from the cylinder block.
71. Remove the bearings from the lower cylinder block.
72. Remove the crankshaft main bearings from the cylinder block.
73. Inspect the cylinder block, lower cylinder block, cylinder heads, pistons and connecting rods.

Scheme 358

1. Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and valve tappet for damage.

Scheme 359

Note. Specifications show the expected minimum or maximum condition. See SPECIFICATIONS .

Note. If a component fails to meet the specifications, it is necessary to install a new component or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. A new component must be installed for any component that fails to meet specifications and cannot be refinished.

1. Inspect the timing chain/belt and the sprockets. Install new components as necessary.

Scheme 360

Scheme 361

Scheme 362

Scheme 363

1. Remove the hydraulic lash adjusters.
2. Using the special tool, remove the keys, retainer, and spring.
3. Remove the valve from the cylinder head.
4. Remove the valve stem seal.
5. Using the special tool, remove the valve guide from the cylinder head.

Scheme 364

Scheme 365

Scheme 366

Scheme 367

1. Using the special tool, install the valve guide.
2. Using the special tool, install the valve stem seal.
3. Install the valve.
4. Using the special tool, install the valve spring, retainer and key.
5. Install the hydraulic lash adjusters.

Scheme 368

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Scheme 440

1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. If removed, install the crankshaft key into the key-way on the crankshaft.
3. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block rear face. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2. The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2,3 and 4 should all be grade 2.
5. Install the main bearings into the cylinder block.
6. Install the main bearings into the lower cylinder block.
7. Install the crankshaft thrust bearing.
8. Apply SAE 5W-20 motor oil to the crankshaft main and rod bearing journals.
9. Position the crankshaft in the cylinder block. CAUTION: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.
10. Apply Silicone Gasket and Sealant to the cylinder block as shown.
11. Position the lower cylinder block and install the bolts and studs. Tighten the bolts and studs in the sequence shown in four stages. Stage 1: Tighten fasteners 1-8 to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Stage 2: Tighten fasteners 9-19 to 40 N.m {4.1 kgf.m, 30 ft.lbf>. Stage 3: Tighten fasteners 1-16 90 degrees. Stage 4: Tighten fasteners 17-22 to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
12. Using the special tool, measure the crankshaft end play. See «CRANKSHAFT -- END PLAY»(ref-221815-S14855317322006022600000) .
13. Using the special tool, install the crankshaft rear oil seal.
14. Position the flexplate and install the bolts.
15. Mount the engine on an engine stand.
16. Apply SAE 5W-20 motor oil to the cylinder bores.
17. Using the special tools, install the piston and connecting rod assemblies.
18. Check connecting rod bearing clearance.
19. Install the connecting rod caps and bolts. Tighten the bolts in two stages. Stage 1: Tighten to 23 N.m {2.3 kgf.m, 17 ft.lbf}. Stage 2: Tighten to 43 N.m {4.4 kgf.m, 32 ft.lbf}.
20. Position the oil pump and install the bolts in the indicated sequence.
21. Position the oil pan baffle and install the nuts. Tighten the nuts in two stages. Stage 1: Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf}. Stage 2: Tighten 45 degrees.
22. Install a new O-ring seal on the oil pump screen and pick-up tube.
23. Install the oil pump screen and pick up tube. Position the oil pump screen and pick up tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf}. Stage 2: Tighten 45 degrees.
24. Install the power steering/engine support bracket.
25. Install the oil separator. Install the two bolts.
26. Position the LH and RH cylinder heads, gaskets, and install the bolts. Tighten the bolts in the sequence shown in six stages. Stage 1: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 2: Tighten to 90 N.m {9.2 kgf.m, 66 ft.lbf}. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}. Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position to locate top dead center (TDC).
28. Apply SAE 5W-20 motor oil to the LH and RH camshaft followers.
29. Install the LH and RH camshaft followers.
30. Apply SAE 5W-20 motor oil to the LH and RH camshafts.
31. Install the LH and RH camshafts. Locate the camshafts as shown.
32. Position the LH camshaft caps and install the bolts in the sequence shown.
33. Position the RH camshaft caps and install the bolts in the sequence shown.
34. Remove the crankshaft damper bolt.
35. Install the crankshaft sprockets.
36. Position the chain tensioner in a soft-jawed vise.
37. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
38. Slowly compress the timing chain tensioner.
39. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
40. If timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Count 29 links counterclockwise from the crankshaft timing mark (including the starting link) and mark this link as the (LH chain Exhaust / RH chain Intake) cam sprocket timing mark. Continue counting counterclockwise to 42 and mark this link as the (LH chain Exhaust / RH chain Intake) sprocket timing mark.
41. Position the guide and install the bolts.
42. Install the LH timing chain. Position number one on the crankshaft. Count twenty-nine links from the number one link. Position on the exhaust cam sprocket. Continue counting to forty-two and position link on intake sprocket timing mark.
43. Install the LH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
44. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position.
45. Verify that the RH camshafts are correctly positioned.
46. Install the RH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
47. Install the RH timing chain guide and install the bolts.
48. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
49. Remove the LH and RH timing chain tensioner piston retaining wires.
50. Remove the crankshaft damper bolt.
51. Verify the timing with the following steps. There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and crankshaft timing marks. There should be 30 chain links between the camshaft and crankshaft timing marks.
52. Install the ignition pulse wheel.
53. Install the special tool to hold the flexplate.
54. Install three gaskets in the front cover. NOTE: The front cover must be installed and the bolts tightened within six minutes of sealant application.
55. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
56. Position the front cover and install the bolts and studs in the sequence shown.
57. Using the special tool, install the crankshaft front oil seal.
58. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover to cylinder block mating surface.
59. Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
60. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 in) -0.25 mm (0.009 in) under flush. Assemblies that are between 0.26 (0.01 in) -0.50 mm (0.019 in) should be shimmed using either one or two 0.25 mm (0.009 in) gold shims. Assemblies that are between 0.51 mm (0.20 in) -0.75 mm (0.029 in) should be shimmed using either one or two 0.50 mm (0.019 in) silver shims. If the pan measures greater than 0.75 mm (0.029 in) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
61. Tighten the oil pan bolts and studs in the sequence shown.
62. Install a new seal on the oil level indicator tube.
63. Install the oil level indicator tube and install the bolt.
64. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
65. Using the special tool, install the crankshaft vibration damper.
66. Install the crankshaft vibration damper washer and bolt. Tighten the bolt in four stages. Stage 1: Tighten to 120 N.m {1.22 kgf.m, 89 ft.lbf}. Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 N.m {5.1 kgf.m, 37 ft.lbf}. Stage 4: Tighten to 90 N.m {9.2 kgf.m, 66 ft.lbf}.
67. Install new gaskets in the valve covers.
68. Apply a 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
69. Position the RH valve cover and install the bolts and studs in the sequence shown.
70. Position the LH valve cover and install the bolts and studs in the sequence shown.
71. Install the spark plugs.
72. Install the six coil-on-plugs and install the bolts.
73. Position the gasket and install the lower intake manifold.
74. Remove the special tool.
75. Position the coolant bypass tube and connect the hoses.
76. Install the oil pressure sender and the block heater.
77. Install the oil cooler.
78. Install the radio ignition noise suppressor electrical connector.
79. Install the generator support bracket.
80. Install the power steering pump.
81. Install the power steering pump pulley.
82. Install the oil filter.
83. Connect the coolant hoses at the oil cooler.
84. Install the water pump assembly.
85. Connect the hoses. Vehicles not equipped with water pump belt tensioner
86. Install the water pump belt on the water pump pulley and position it on the camshaft pulley.
87. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley. Vehicles equipped with water pump belt tensioner
88. Rotate the belt tensioner clockwise and install the water pump belt.
89. Install the water pump belt cover. All vehicles
90. Position a new gasket and tighten the LH exhaust manifold nuts in the sequence shown.
91. Install the engine lift bracket.
92. Position and connect the engine control sensor wiring to the following components: coils on plugs fuel injectors
93. Connect the radio interference capacitor.
94. Connect the crankshaft and camshaft position sensor electrical connectors.
95. Install new gaskets in the upper intake manifold.
96. Install the upper intake manifold.
97. Install and connect the engine control wire harness.
98. Connect the coolant temperature sender and the oil pressure switch.
99. Connect the vacuum line to the fuel pressure damper.
100. Connect the engine control sensor wiring to the upper intake manifold.
101. Connect the EGR vacuum regulator and the differential pressure feedback EGR electrical connectors.
102. Install the PCV tube.
103. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

Scheme 441

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Scheme 487

Scheme 488

1. Using the special tools remove the engine from the engine stand and position it with the transaxle on the subframe.
2. Install the six bolts in the transaxle.
3. Using the special tools, position the powertrain on the universal powertrain lift.
4. Using a bracket from a heavy duty engine stand, support the front of the engine.
5. Position the halfshaft bracket and install the bolts.
6. Install a new gasket and the RH exhaust manifold.
7. Install the generator.
8. Install the EGR tube and connect the DPFE.
9. Tighten the exhaust gas recirculation (EGR) tube and the heated oxygen sensor (HO2S) electrical connector.
10. Connect the output shaft speed (OSS) sensor and turbine shaft speed (TSS) sensor electrical connectors.
11. Install the starter.
12. Install the bolt and connect the transaxle control harness to the bracket.
13. Connect the transaxle harness.
14. Connect the transaxle range sensor.
15. Connect the heated oxygen sensors.
16. Position the powertrain in the vehicle.
17. Install the two bolts for the motor mount support.
18. Install the two subframe side nuts.
19. Install the two rear subframe bolts.
20. Position the transaxle mount and install the bolts.
21. Connect the power steering return hose.
22. Install the motor mount bracket bolts and the nuts.
23. Remove the bracket.
24. Remove the universal powertrain lift.
25. If equipped connect the block heater wiring.
26. Install the four bolts.
27. Install the four torque converter nuts.
28. Install the inspection plug.
29. Connect the two transaxle cooler lines.
30. Connect the steering shaft to the rack and install the bolt.
31. Connect the LH and RH struts to the steering knuckles and install the bolts.
32. Install the brake calipers to the steering knuckle.
33. If equipped, install the LH and RH wheel speed sensor harness brackets.
34. If equipped, position the LH and RH wheel speed sensors and install the bolts.
35. Connect the LH and RH sway bar links to the strut mount.
36. If equipped, install the intermediate drive shaft. See «INTERMEDIATE SHAFT»(ref-221881-S20838121272006022600000) .
37. Install both front wheel and tire assemblies.
38. Install the A/C compressor. See «AIR CONDITIONING (A/C) COMPRESSOR -- 3.0L (4V)»(ref-221930-S29186547602006022600000) .
39. Install the exhaust flexible pipe. See «EXHAUST FLEXIBLE PIPE -- 3.0L (4V)»(ref-221829-S34988247892006022600000) .
40. Install the lower radiator air deflectors.
41. Lower the vehicle.
42. Install the oil level indicator.
43. Position the wire harness and install the wire harness locating retainers.
44. Connect the ground strap and the electrical connector.
45. Connect the power steering line. Install the bracket bolt. Connect the power steering pressure (PSP) switch electrical connector. Connect the power steering line.
46. Connect the power steering return line.
47. Connect the heater hoses.
48. Connect the vacuum line at the vacuum reservoir check valve.
49. Connect the brake booster vacuum hose.
50. Connect the transaxle linkage.
51. Install the cables and the nuts.
52. Install the power distribution box cover.
53. Connect the connector to the power distribution box.
54. Position the thermostat housing and connect the five hoses.
55. Install a new tie strap.
56. Connect the ground wire.
57. Connect the powertrain control module (PCM) electrical connector.
58. Connect the vapor management valve (VMV) electrical connector.
59. Connect the accelerator cable and cruise control actuator cable.
60. Connect the fuel line. See «QUICK RELEASE COUPLING -- DOUBLE LOCKING»(ref-221826-S01352047912006022600000) .
61. Install the air cleaner outlet tube and air cleaner. See «AIR CLEANER»(ref-221824-S36617722532006022600000) .
62. Install the battery and the battery tray. See «BATTERY TRAY -- 3.0L (4V)»(ref-221834-S22239518422006022600000) .
63. Install the water pump drive belt.
64. Refill the engine cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-221821-S22848327452006022600000) .
65. Refill the crankcase with SAE 5W-20 motor oil.
66. Fill and purge the power steering system. See «PURGING»(ref-221919-S13343049202006022600000) .
67. Recharge the A/C system. See «AIR CONDITIONING (A/C) SYSTEM EVACUATION AND CHARGING»(ref-221929-S34234551262006022600000) .

Scheme 489

1. Remove the transaxle. See «TRANSAXLE -- 3.0L (4V)»(ref-221909-S42043775782006022600000) .
2. Remove the bolts and the flexplate.
3. To install, reverse the removal procedure.