Engine - 3.0L 2V: Removal & Installation Mercury Sable IV

Removal

1. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
2. Remove the crankshaft oil seal (6700).

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1. Install the crankshaft oil seal. Lubricate the seal lip with clean engine oil. Install the crankshaft oil seal.
2. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .

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1. Drain the engine coolant.
2. Disconnect the battery ground cable (14301).
3. Remove the engine anti-roll strut brace. Remove the nuts. Remove the brace.
4. Remove the engine anti-roll strut. Remove the bolts.
5. Remove the coolant expansion tank (8A080). Refer to ENGINE COOLING .
6. Loosen the four water pump pulley bolts.
7. Remove the crankshaft damper (6316). Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
8. Disconnect the lower radiator hose. Reposition the clamp. Disconnect the hose.
9. Remove the crankshaft position (CKP) sensor (6C315). Disconnect the sensor. Remove the bolts. Remove the sensor.
10. Remove the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
11. Lower the vehicle.
12. Disconnect the generator (10346).
13. Remove the generator support bracket. Remove the nut. Remove the bolt.
14. Remove the generator. Remove the stud bolt.
15. Remove the accessory drive belt idler pulley. Remove the bolt.
16. Remove the accessory drive belt tensioner (6B209). Remove the bolt.
17. Remove the A/C compressor bracket. Remove the nut. Remove the bolt.
18. Disconnect the heater hose (18472). Reposition the clamp. Disconnect the hose.
19. Remove the water pump pulley (8509). Remove the bolts. Remove the pulley.
20. Remove the engine front cover (6059) and water pump (8501) as an assembly. Remove the bolts. Remove the front cover.
21. Remove and discard the front cover gasket (6020).

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1. Clean all sealing surfaces and position a new front cover gasket.
2. Install the engine front cover and water pump assembly. Apply Pipe Sealant with Teflon® to the bolts indicated. Install the bolts.
3. Install the water pump pulley.
4. Connect the heater hose. Connect the hose. Position the clamp.
5. Install the A/C compressor bracket. Position the bracket. Install the bolt. Install the nut.
6. Install the accessory drive belt tensioner.
7. Install the accessory drive belt idler pulley.
8. Install the generator. Install the stud bolt.
9. Install the generator support bracket. Position the bracket. Install the bolt. Install the nut.
10. Connect the generator electrical connectors.
11. Raise the vehicle on a hoist.
12. Install the crankshaft position (CKP) sensor. Position the sensor. Install the bolts. Connect the connector.
13. Connect the lower radiator hose. Connect the hose. Reposition the clamp.
14. Install the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
15. Install the crankshaft damper. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
16. Install the coolant expansion tank.
17. Install the engine anti-roll strut.
18. Install the engine anti-roll strut brace.
19. Connect the battery.
20. Fill and bleed the cooling system. Refer to «BLEEDING»(ref-139103-S23703246542002042500000) .

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1. Drain the engine coolant.
2. Disconnect the battery ground cable (14301).
3. Remove the engine anti-roll strut brace. Remove the nuts. Remove the brace.
4. Remove the engine anti-roll strut. Remove the bolts.
5. Remove the coolant expansion tank (8A080).
6. Loosen the four water pump pulley bolts.
7. Remove the crankshaft damper (6316). Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
8. Disconnect the lower radiator hose. Reposition the clamp. Disconnect the hose.
9. Remove the crankshaft position (CKP) sensor (6C315). Disconnect the sensor. Remove the bolts. Remove the sensor.
10. Remove the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
11. Lower the vehicle.
12. Disconnect the generator (10346).
13. Remove the generator cable bracket bolt.
14. Remove the generator support bracket. Remove the nut. Remove the bolt.
15. Remove the bolts and the generator.
16. Remove the power steering pump. Refer to «POWER STEERING PUMP -- 3.0L (2V) CIII»(ref-178432-S02155723522005061500000) .
17. Remove the accessory drive belt tensioner (6B209). Remove the bolts.
18. Remove the bolts and the front end accessory drive mounting bracket.
19. Remove the support bracket. Remove the nut. Remove the bolt.
20. Disconnect the heater hose (18472). Reposition the clamp. Disconnect the hose.
21. Remove the water pump pulley (8509). Remove the bolts. Remove the pulley.
22. Remove the engine front cover (6059) and water pump (8501) as an assembly. Remove the bolts. Remove the front cover.
23. Remove and discard the front cover gasket (6020).

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1. Clean all sealing surfaces and position a new front cover gasket.
2. Install the engine front cover and water pump assembly. Apply Pipe Sealant with Teflon® to the bolts indicated. Install the bolts.
3. Install the water pump pulley.
4. Connect the heater hose. Connect the hose. Position the clamp.
5. Install the support bracket. Position the bracket. Install the bolt. Install the nut.
6. Install the front end accessory drive bracket and bolts.
7. Install the accessory drive belt tensioner.
8. Install the power steering pump. Refer to «POWER STEERING PUMP -- 3.0L (2V) CIII»(ref-178432-S02155723522005061500000) .
9. Install the generator and the bolts.
10. Install the generator support bracket. Position the bracket. Install the bolt. Install the nut.
11. Install the alternator cable bracket.
12. Connect the generator.
13. Raise the vehicle on a hoist.
14. Install the crankshaft position (CKP) sensor. Position the sensor. Install the bolts. Connect the connector.
15. Connect the lower radiator hose. Connect the hose. Reposition the clamp.
16. Install the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
17. Install the crankshaft damper. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
18. Install the coolant expansion tank. Refer to ENGINE COOLING .
19. Install the engine anti-roll strut.
20. Install the engine anti-roll strut brace.
21. Connect the battery.
22. Fill and bleed the cooling system. Refer to «BLEEDING»(ref-139103-S23703246542002042500000) .

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1. Remove the valve covers (6582). Refer to «VALVE COVER - RH»(ref-178530-S04144320292005061600000) or «VALVE COVER - LH»(ref-178530-S30561256242005061600000) .
2. Remove the rocker arms. Remove the bolts.
3. To install, reverse the removal procedure. Tighten the bolts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 32 Nm (24 lb-ft).

Removal and Installation

1. Remove the rocker arms. Refer to «ROCKER ARMS»(ref-178530-S27496248442005061600000) .
2. Remove the push rods.
3. To install, reverse the removal procedure.

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1. Remove the rocker arms. Refer to «ROCKER ARMS»(ref-178530-S27496248442005061600000) .
2. Rotate the crankshaft (6303) until the piston (6108) for the valve being worked on is at the top of its stroke with both the intake valve (6507) and the exhaust valve (6505) closed.
3. Hold the valve in the cylinder head (6049). Remove the spark plug (12405). Refer to «SPARK PLUG»(ref-142370-S36810629412002101700000) . Apply a minimum of 689 kPa (100 psi) of compressed air to the cylinder.
4. Using the special tool, remove the valve spring retainer keys (6518).
5. Remove the valve spring retainer. Refer to «VALVE TRAIN ANALYSIS-ENGINE OFF, VALVE SPRING RETAINER AND VALVE SPRING RETAINER KEYS»(ref-178685-S42042465892005062000000) for component tests for the valve spring retainer.
6. Remove the valve spring (6513). Refer to «VALVE TRAIN ANALYSIS--VALVE SPRINGS»(ref-178685-S32996904482005062000000) for component tests for the valve spring.
7. Remove the valve stem seal (6571).
8. To install, reverse the removal procedure.

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Note. For a valve train noise concern, inspect the valve-to-rocker arm clearance, rocker arms and push rods for wear. For additional information, refer to VALVE TRAIN ANALYSIS - ENGINE OFF - VALVE COVER REMOVED

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1. Remove the lower intake manifold (9424). Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
2. Remove pushrods. Refer to «PUSH ROD»(ref-178530-S20412646762005061600000) .
3. Remove the tappet guide plate retainer.
4. Remove the valve tappet guide plates (6K512).
5. Remove the valve tappets (6500).

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1. Install the valve tappets.
2. Install the valve tappet guide plates.
3. Install the tappet guide plate retainer.
4. Install the pushrods. Refer to «PUSH ROD»(ref-178530-S20412646762005061600000) .
5. Install the lower intake manifold. Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
6. Connect the battery ground cable.

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1. Remove the engine front cover (6019). Refer to «ENGINE FRONT COVER - WITH CIII POWER STEERING SYSTEM»(ref-178530-S38129962022005061600000) OR «ENGINE FRONT COVER - WITH CII POWER STEERING SYSTEM»(ref-178530-S02452693942005061600000) .
2. Rotate the crankshaft (6303) and align the timing marks.
3. Remove the camshaft sprocket bolt.
4. Remove the timing chain (6268), the camshaft sprocket (6256) and the crankshaft sprocket (6306) as an assembly.

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1. Align the timing marks.
2. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
3. Install the camshaft sprocket bolt.
4. Install the engine front cover. Refer to «ENGINE FRONT COVER - WITH CIII POWER STEERING SYSTEM»(ref-178530-S38129962022005061600000) OR «ENGINE FRONT COVER - WITH CII POWER STEERING SYSTEM»(ref-178530-S02452693942005061600000) .
5. Connect the battery ground cable.

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1. Disconnect the battery ground cable (14301).
2. Remove the cowl vent screen and cowl extension.
3. Disconnect the oxygen sensor (HO2S) (9F472) electrical connector.
4. Remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube.
5. Remove the exhaust manifold heat shield. Remove the bolts. Remove the heat shield.
6. Disconnect the catalytic converter from the exhaust manifold. Remove the bolts.
7. Remove the six bolts and the exhaust manifold. Remove the six bolts.
8. Remove the RH exhaust manifold (9430) and the exhaust manifold gasket (9448). Discard the exhaust manifold gasket.

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1. Position a new exhaust manifold gasket and install the exhaust manifold.
2. Install the bolts. Tighten in the sequence shown, in two stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
3. Connect the catalytic converter. Install the bolts.
4. Install the exhaust manifold heat shield. Install the bolts.
5. Install the exhaust manifold to exhaust gas recirculation (EGR) valve tube.
6. Connect the HO2S electrical connector.
7. Install the cowl vent screen and cowl extension.
8. Connect the battery ground cable.

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1. Disconnect the battery ground cable (14301).
2. Disconnect the Heated Oxygen Sensor (HO2S) (9F472) electrical connector.
3. Remove the oil level indicator tube (6754). Remove the nut. Remove the tube.
4. Disconnect the power steering pressure line (3A714) from the power steering pump. Loosen the compression nut.
5. Position the power steering pressure line aside. Remove the nut.
6. If equipped, disconnect the secondary air injection tube from the exhaust manifold (9431). Loosen the compression nut.
7. Separate the dual converter Y-pipe from the exhaust manifold. Remove the nuts.
8. Remove the four exhaust manifold bolts and two stud bolts.
9. Remove the exhaust manifold and the exhaust manifold gasket (9448). Discard the exhaust manifold gasket.

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1. Position a new exhaust manifold gasket (9448) and install the exhaust manifold.
2. Install the bolts. Tighten the bolts in sequence in two stages: Tighten to 10 Nm (8 lb-ft). Tighten to 22 Nm (16 lb-ft).
3. Connect the dual converter Y-pipe to the exhaust manifold. Install the nuts.
4. If equipped, connect the secondary air injection tube to the exhaust manifold.
5. Reposition the power steering pressure line and install the nut.
6. Using the special tool, install a new seal on the power steering pressure line.
7. Connect the power steering pressure line to the power steering pump.
8. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
9. Install the oil level indicator tube.
10. Connect the HO2S electrical connector.
11. Connect the battery.

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1. Disconnect the battery ground cable (14301).
2. Disconnect the heated oxygen sensor (HO2S) (9F472) electrical connector.
3. Remove the oil level indicator tube (6754). Remove the nut. Remove the tube.
4. Remove the power steering pump pulley. Refer to «POWER STEERING PUMP PULLEY - CIII PUMP»(ref-178432-S28143542472005061500000) .
5. Disconnect the power steering pressure line (3A714) from the power steering pump. Loosen the compression nut.
6. Position the power steering pressure line aside. Remove the nut.
7. Separate the dual converter Y-pipe from the exhaust manifold. Remove the nuts.
8. Remove the four exhaust manifold bolts and two studs bolts.
9. Remove the exhaust manifold and the exhaust manifold gasket (9448). Discard the exhaust manifold gasket.

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1. Position a new exhaust manifold gasket (9448) and install the exhaust manifold.
2. Install the bolts. Tighten the bolts in sequence in two stages: Tighten to 10 Nm (8 lb-ft). Tighten to 22 Nm (16 lb-ft).
3. Connect the dual converter Y-pipe to the exhaust manifold. Install the nuts.
4. Reposition the power steering pressure line and install the nuts.
5. Using the special tool, install a new seal on the power steering pressure line.
6. Connect the power steering pressure line to the power steering pump.
7. Install the power steering pump pulley. Refer to «POWER STEERING PUMP PULLEY - CIII PUMP»(ref-178432-S28143542472005061500000) .
8. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
9. Install the oil level indicator tube.
10. Connect the HO2S electrical connector.
11. Connect the battery.

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1. Remove the lower intake manifold (9424). Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
2. Disconnect the crankshaft position sensor (CKP) electrical connector.
3. Disconnect the oxygen sensor (HO2S) electrical connector.
4. Disconnect the wire harness ground connections. Remove the screw.
5. Disconnect the powertrain control module (PCM) electrical connector. Loosen the bolt. Disconnect the electrical connector.
6. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector.
7. Position the spark plug wires aside. Disconnect the spark plug wires.
8. Disconnect the exhaust gas recirculation (EGR) tube. Loosen the compression nut.
9. Remove the exhaust manifold heat shield. Remove the three bolts.
10. Loosen the exhaust manifold-to-catalytic converter bolts.
11. Remove the six exhaust manifold-to-cylinder head bolts.
12. Disconnect the engine wire harness locator.
13. Separate the catalytic converter heat shield from the cylinder head. Remove the bolt.
14. Remove the eight cylinder head bolts.
15. Remove the cylinder head (6049).
16. Remove the discard the head gasket (6051).

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1. Clean all the sealing surfaces.
2. Check the cylinder head and cylinder block for flatness. Refer to «CYLINDER HEAD - DISTORTION»(ref-178685-S19778527422005062000000) .
3. Position a new cylinder head gasket.
4. Position the cylinder head.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate each bolt 90 degrees. Stage 5: Rotate each bolt an additional 90 degrees.
6. Install the catalytic converter heat shield and wire harness ground connection. Install the bolt.
7. Reposition the wire harness and install the harness locator.
8. Install the exhaust manifold-to-cylinder head bolts and tighten in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 22 Nm (16 lb-ft).
9. Tighten the exhaust manifold-to-catalytic converter bolts.
10. Install the exhaust manifold heat shield.
11. Install the EGR tube. Tighten the compression nut.
12. Reposition and connect the spark plug wires.
13. Connect the EVAP canister purge valve electrical connector.
14. Connect the PCM electrical connector.
15. Connect the wire harness ground connections. Install the screw.
16. Connect the HO2S electrical connector.
17. Connect the CKP electrical connector.
18. Install the lower intake manifold. Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
19. Connect the battery ground cable.

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1. Remove the lower intake manifold (9424). Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
2. Remove the accessory drive belt.
3. Remove the engine anti-roll strut brace. Remove the nuts.
4. Disconnect the generator electrical connector.
5. Remove the generator. Remove the bolt. Remove the stud bolt.
6. Remove the accessory drive belt idler pulley. Remove the bolt.
7. Remove the accessory drive belt tensioner pulley. Remove the bolt.
8. Remove the spark plug wires.
9. Remove the LH exhaust manifold. Refer to «EXHAUST MANIFOLD - LH WITH CII POWER STEERING SYSTEM»(ref-178530-S30492242772005061600000) .
10. Remove the power steering pump and bracket assembly. Disconnect the power steering return hose. Remove the bolt. Remove the two nuts.
11. Remove the eight cylinder head bolts.
12. Remove the cylinder heads (6049).
13. Remove and discard the head gaskets (6051).

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1. Clean all the sealing surfaces.
2. Check the cylinder head and the cylinder block for flatness. Refer to «CYLINDER HEAD - DISTORTION»(ref-178685-S19778527422005062000000) .
3. Position a new cylinder head gasket.
4. Position the cylinder head.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate an additional 90 degrees. Stage 5: Rotate an additional 90 degrees.
6. Install the power steering pump and bracket assembly. Install the bolt. Install the two nuts. Connect the power steering return hose.
7. Install the LH exhaust manifold. Refer to «EXHAUST MANIFOLD - LH WITH CII POWER STEERING SYSTEM»(ref-178530-S30492242772005061600000) .
8. Install the spark plug wires.
9. Install the accessory drive belt tensioner. Install the bolt.
10. Install the accessory drive belt idler pulley. Install the bolt.
11. Install the generator. Install the stud bolt. Install the bolt.
12. Connect the generator electrical connectors.
13. Install the engine anti-roll strut brace. Install the two nuts.
14. Install the accessory drive belt. Refer to «DRIVE BELT ROUTING»(ref-139103-S33285511932002042500000) .
15. Install the lower intake manifold. Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
16. Connect the battery ground cable.

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1. Remove the lower intake manifold (9424). Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
2. Remove the accessory drive belt.
3. Remove the engine anti-roll strut brace. Remove the nuts.
4. Remove the power steering pump. Refer to «POWER STEERING PUMP -- 3.0L (2V) CIII»(ref-178432-S02155723522005061500000) .
5. Disconnect the generator electrical connectors.
6. Remove the generator cable bracket bolt.
7. Remove the bolts and the generator.
8. Remove the accessory drive belt tensioner. Remove the bolts.
9. Remove the spark plug wires.
10. Remove the LH exhaust manifold. Refer to «EXHAUST MANIFOLD LH - WITH CIII POWER STEERING SYSTEM»(ref-178530-S38779832932005061600000) .
11. Remove the bolts and the front end accessory drive bracket assembly.
12. Remove the eight cylinder head bolts.
13. Remove the LH cylinder head (6049).
14. Remove and discard the head gaskets (6051).

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1. Clean all the sealing surfaces.
2. Check the cylinder head and the cylinder block for flatness. Refer to «CYLINDER HEAD -- DISTORTION»(ref-178685-S19778527422005062000000) .
3. Position a new cylinder head gasket.
4. Position the cylinder head.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate an additional 90 degrees. Stage 5: Rotate an additional 90 degrees.
6. Install the front end accessory drive bracket assembly and bolts.
7. Install the LH exhaust manifold. Refer to «EXHAUST MANIFOLD LH - WITH CIII POWER STEERING SYSTEM»(ref-178530-S38779832932005061600000) .
8. Install the spark plug wires.
9. Install the accessory drive belt tensioner. Install the bolt.
10. Install the generator and the bolts.
11. Install the generator cable bracket bolt.
12. Connect the generator electrical connectors.
13. Install the engine anti-roll strut brace. Install the two nuts.
14. Install the power steering pump. Refer to «POWER STEERING PUMP -- 3.0L (2V) CIII»(ref-178432-S02155723522005061500000) .
15. Install the accessory drive belt. Refer to «DRIVE BELT ROUTING»(ref-139103-S33285511932002042500000) .
16. Install the lower intake manifold. Refer to «INTAKE MANIFOLD - LOWER»(ref-178530-S02768589572005061600000) .
17. Connect the battery ground cable.

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1. Disconnect the oil pressure switch electrical connector.
2. Remove the oil pressure switch.
3. To install, reverse the removal procedure.

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1. Remove the oil level indicator and tube (6754). Remove the nut. Remove the tube.

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1. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
2. Install the oil level indicator tube. Install the tube. Install the nut.

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1. Disconnect the battery ground cable (14301).
2. Raise and support the vehicle.
3. Remove the dual converter Y-pipe (5F250).
4. Remove the starter motor (11002). Refer to «STARTER MOTOR»(ref-139462-S06690915192002050100000) .
5. Remove the engine rear plate (7007). Remove the bolt.
6. Drain the engine oil.
7. Remove the oil pan (6675). Remove the 16 bolts.
8. Remove the oil pan gasket from the oil pan. Clean the oil pan-to-cylinder block sealing surface.

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1. Install the oil pan gasket onto the oil pan.
2. Apply a bead of silicone gasket and sealant in two places where the cylinder block meets the front cover and in two places where the rear main bearing cap meets the cylinder block.
3. Position the oil pan and install the 16 bolts. Tighten the bolts in three stages: Stage 1: Tighten the four corner bolts to 12 Nm (9 lb-ft). Stage 2: Tighten the remaining bolts from back to front to 12 Nm (9 lb-ft). Stage 3: Check all bolts for correct tightness.
4. Install the engine rear plate. Install the bolt
5. Install the starter motor. Refer to «STARTER MOTOR»(ref-139462-S06690915192002050100000) .
6. Install the dual converter Y-pipe.
7. Lower the vehicle.
8. Fill the engine with clean engine oil.
9. Connect the battery ground cable.
10. Start the engine and allow it to reach normal operating temperature.
11. Stop the engine.
12. Raise and support the vehicle.
13. Retighten the oil pan bolts from the back to front to 12 Nm (9 lb-ft).
14. Inspect the oil pan gasket for correct alignment.
15. Lower the vehicle.

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1. Remove the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
2. Remove the seven nuts and remove the oil pan baffle.
3. To install, reverse the removal procedure.

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1. Remove the oil pan (6675). Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
2. Remove the oil pump (6600). Remove the bolt.
3. Clean all the sealing surfaces.
4. If an internal inspection is required, remove the oil pump cover.
5. To install, reverse the removal procedure.

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1. Remove the transaxle. Refer to «TRANSAXLE (AX4S)»(ref-155920-S11529239252003063000000) or «TRANSAXLE (4F50N)»(ref-155920-S05811784192003082500000) .
2. Remove the flexplate. Remove the bolts.
3. To install, reverse the removal procedure.

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1. Remove the flexplate. Refer to «FLEXPLATE»(ref-178530-S11532300302005061600000) .
2. Using a sharp awl, punch one hole into the crankshaft rear oil seal metal surface between the seal lip and the cylinder block.
3. Screw the threaded end of the special tool into the oil seal. Use the special tool to remove the crankshaft rear oil seal.

Scheme 308

1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.
2. Using the special tool, install the crankshaft rear oil seal. Alternate bolt tightening to correctly seat the crankshaft rear oil seal.
3. Install the flexplate. Refer to «FLEXPLATE»(ref-178530-S11532300302005061600000) .

Scheme 309

Scheme 310

Scheme 311

1. Remove the oil pan (6675). Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
2. If necessary, remove the oil pump. Refer to «OIL PUMP»(ref-178530-S31926833992005061600000) .
3. Remove one crankshaft main bearing cap.
4. Remove the crankshaft main bearings.

Scheme 312

1. Install the crankshaft main bearing.
2. Install the crankshaft main bearing cap.
3. Repeat the procedure until all the crankshaft main bearings are replaced.
4. If removed, install the oil pump. Refer to «OIL PUMP»(ref-178530-S31926833992005061600000) .
5. Install the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .

Scheme 313

Scheme 314

1. Remove the oil pan (6675). Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .
2. If necessary, remove the oil pump. Refer to «OIL PUMP»(ref-178530-S31926833992005061600000) .
3. Remove the connecting rod bearing cap.
4. Remove the connecting rod bearings (6211).

Scheme 315

1. Install the connecting rod bearings.
2. Install the connecting rod bearing cap.
3. Repeat the procedure until all the connecting rod bearings are replaced.
4. If removed, install the oil pump. Refer to «OIL PUMP»(ref-178530-S31926833992005061600000) .
5. Install the oil pan. Refer to «OIL PAN»(ref-178530-S31080861322005061600000) .

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Scheme 327

1. Remove the air cleaner and the air cleaner outlet tube.
2. Remove the cowl vent screen and cowl extension.
3. Remove the engine anti-roll strut. Remove the two bolts.
4. Install the engine lift bracket.
5. Remove the catalytic converters.
6. Remove the valance panel. Remove three screws. Remove nine pin-type retainers.
7. Remove the RH catalytic converter heat shield. Remove the bolt. Remove the two nuts.
8. Remove the RH engine support insulator-to-subframe nut.
9. Remove the LH engine support insulator-to-subframe nut.
10. Remove the LH front wheel assembly.
11. Remove the nut and two bolts retaining the rear engine support insulator.
12. Partially lower the vehicle.
13. Using the special tool, lift the engine 5.08 cm (2.0 in).
14. Remove the rear engine support insulator.
15. Remove the RH engine support insulator. Remove the through bolt.
16. Remove the LH engine support insulator. Remove the bolts.
17. To install, reverse the removal procedure.

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Scheme 395

1. Disconnect the battery ground cable (14301).
2. Drain the engine cooling system. Refer to ENGINE COOLING .
3. Remove the cowl vent screen and cowl extension.
4. Remove the engine air cleaner (ACL) (9600) and the air cleaner outlet tube (9B659).
5. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-178710-S17932127632005062100000) .
6. Relieve the fuel system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-142370-S36646181352002073100000) .
7. Position the steering column input shaft coupling boot aside. Remove the three nuts.
8. Separate the steering column from the steering gear. Loosen the pinch bolt and slide the coupling off the steering gear input shaft.
9. Remove the snow shield. Remove the pin-type retainers.
10. Disconnect the accelerator cable (9A758), speed control actuator cable (9A825) and the throttle return spring from the throttle body.
11. Position the accelerator cable bracket aside. Remove the bolts.
12. Disconnect the chassis vacuum hose.
13. Disconnect the manual control lever cable. Remove the nut.
14. Disconnect the manual control lever cable from the bracket and position aside.
15. Loosen the bolt and disconnect the 42-pin and Transmission Range (TR) sensor electrical connectors.
16. Disconnect the upper radiator hose and the heater water hose from the thermostat housing.
17. Remove the battery.
18. Disconnect the ground strap electrical connector. Remove the nut.
19. Disconnect the LH exhaust manifold flange. Remove the nuts.
20. Disconnect the power steering return hose.
21. Disconnect the generator electrical connectors and position the wire harness aside.
22. Disconnect the A/C suction tube from the accumulator drier.
23. Disconnect the fuel supply hose. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
24. Remove the engine roll restrictor brace. Remove the nuts.
25. Remove the engine roll restrictor. Remove the bolts.
26. Disconnect the degas hose from the degas bottle.
27. Disconnect the heater water hose.
28. Disconnect the ground electrical connectors. Remove the bolt.
29. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector.
30. Disconnect the powertrain control module (PCM) electrical connector. Loosen the bolt.
31. Raise the vehicle on a hoist.
32. Remove the valance panel. Remove the three screws. Remove the nine pin-type retainers.
33. Disconnect the catalyst monitor sensor electrical connector.
34. Disconnect the catalyst monitor sensor electrical connector.
35. Remove the catalytic converters and Y-pipe assemblies.
36. Remove the front wheels.
37. Disconnect the A/C discharge tube. Remove the nut.
38. Disconnect the lower radiator hose from the water pump.
39. Remove the radiator support bracket.
40. Disconnect the lower radiator hose from the radiator and degas bottle supply hose.
41. Disconnect the transmission oil cooler hose.
42. Disconnect the wire harness electrical connector.
43. Disconnect the auxiliary oil cooler assembly. Disconnect the transmission oil cooler hose, if equipped. Disconnect the power steering return hose.
44. Remove the oil pan drain plug and drain the engine oil.
45. Remove the starter motor electrical connector cover.
46. Disconnect the starter motor electrical connectors. Remove the two nuts.
47. Remove the starter motor. Remove the two bolts.
48. Remove the engine rear plate. Remove the bolt.
49. Remove the four torque converter nuts.
50. Disconnect the LH and RH stabilizer links from the stabilizer bar. Remove the nuts.
51. Separate the LH and RH lower control arms from the steering knuckles. Remove the nuts.
52. Separate the LH and RH tie rod ends from the steering knuckles. Remove the nuts.
53. Separate the LH and RH half shafts from the steering knuckles. Remove the nuts.
54. Position the special tool.
55. Remove the four front subframe-to-body bolts.
56. Using the special tool, lower the engine, transmission and subframe assembly out of the vehicle.
57. Remove the power steering pressure line bracket. Remove the nut.
58. Remove the power steering pressure line bracket. Remove the nut.
59. Disconnect the power steering pressure line from the power steering pump.
60. Remove the LH secondary air injection tube. Loosen the compression nuts.
61. Separate the control valve solenoid from the bracket and position aside.
62. Disconnect the secondary air injection valve vacuum tube.
63. Remove the secondary air injection valve and bracket. Remove the two nuts.
64. Disconnect the ignition coil. Disconnect the spark plug wires.
65. Disconnect the ignition coil electrical connector.
66. Disconnect the Output Speed Sensor (OSS) and position the wire harness aside.
67. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
68. Disconnect the transaxle harness electrical connector and position the wire harness aside.
69. Remove the RH catalytic converter heat shield. Remove one bolt. Remove two nuts.
70. Remove the secondary air injection hose.
71. Install the LH engine lifting eye.
72. Install the Rh engine lifting eye.
73. Using the special tools, support the engine.
74. Remove the two RH engine support insulator-to-transmission bolts.
75. Remove the LH engine support insulator-to-subframe nut.
76. Remove the RH engine support insulator through bolt.
77. Remove the transmission to engine bolts. Remove five bolts. Remove one stud bolt.
78. Separate the engine (6007) from the transmission.
79. Remove the flywheel. Remove the six bolts.

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Scheme 459

1. Disconnect the battery ground cable (14301).
2. Drain the engine cooling system. Refer to ENGINE COOLING .
3. Remove the cowl vent screen and cowl extension.
4. Remove the engine air cleaner (ACL) (9600) and the air cleaner outlet tube (9B659).
5. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-178710-S17932127632005062100000) .
6. Relieve the fuel system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-142370-S36646181352002073100000) .
7. Position the steering column input shaft coupling boot aside. Remove the three nuts.
8. Separate the steering column from the steering gear. Loosen the pinch bolt and slide the coupling off the steering gear input shaft.
9. Remove the snow shield. Remove the pin-type retainers.
10. Disconnect the accelerator cable (9A758), speed control actuator cable (9A825) and the throttle return spring from the throttle body.
11. Position the accelerator cable bracket aside. Remove the bolts.
12. Disconnect the chassis vacuum hose.
13. Disconnect the manual control lever cable. Remove the nut.
14. Disconnect the manual control lever cable from the bracket and position aside.
15. Loosen the bolt and disconnect the 42-pin and transmission range (TR) sensor electrical connectors.
16. Disconnect the upper radiator hose and the heater water hose from the thermostat housing.
17. Remove the battery.
18. Disconnect the ground strap electrical connector. Remove the nut.
19. Disconnect the LH exhaust manifold flange. Remove the nuts.
20. Disconnect the power steering return hose.
21. Disconnect the generator electrical connectors and position the wire harness aside.
22. Remove the generator cable bracket bolt.
23. Disconnect the A/C suction tube from the accumulator drier.
24. Disconnect the fuel supply hose. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
25. Remove the engine anti-roll strut brace. Remove the nuts.
26. Remove the engine anti-roll strut. Remove the bolts.
27. Disconnect the degas hose from the degas bottle.
28. Disconnect the heater water hose.
29. Disconnect the ground electrical connectors. Remove the bolt.
30. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector.
31. Disconnect the powertrain control module (PCM) electrical connector. Loosen the bolt.
32. Raise the vehicle on a hoist.
33. Remove the valance panel. Remove the three screws. Remove the nine pin-type retainers.
34. Disconnect the catalyst monitor sensor electrical connector.
35. Disconnect the catalyst monitor sensor electrical connector.
36. Remove the catalytic converters and Y-pipe assemblies.
37. Remove the front wheels.
38. Disconnect the A/C discharge tube. Remove the nut.
39. Disconnect the lower radiator hose from the water pump.
40. Remove the radiator support bracket.
41. Disconnect the lower radiator hose from the radiator and degas bottle supply hose.
42. Disconnect the transmission oil cooler hose.
43. Disconnect the wire harness electrical connector.
44. Disconnect the auxiliary oil cooler assembly. Disconnect the transmission oil cooler hose, if equipped. Disconnect the power steering return hose.
45. Remove the oil pan drain plug and drain the engine oil.
46. Remove the starter motor electrical connector cover.
47. Disconnect the starter motor electrical connectors. Remove the two nuts.
48. Remove the starter motor. Remove the two bolts.
49. Remove the engine rear plate. Remove the bolt.
50. Remove the four torque converter nuts.
51. Disconnect the LH and RH stabilizer links from the stabilizer bar. Remove the nuts.
52. Separate the LH and RH lower control arms from the steering knuckles. Remove the nuts.
53. Separate the LH and RH tie rod ends from the steering knuckles. Remove the nuts.
54. Separate the LH and RH half shafts from the steering knuckles. Remove the nuts.
55. Position the special tool.
56. Remove the four front subframe-to-body bolts.
57. Using the special tool, lower the engine, transmission and subframe assembly out of the vehicle.
58. Remove the power steering pressure line bracket. Remove the nut.
59. Remove the power steering pressure line bracket. Remove the nut.
60. Disconnect the power steering pressure line from the power steering pump.
61. Disconnect the spark plug wires from the ignition coil.
62. Disconnect the ignition coil electrical connector.
63. Remove the ignition coil. Remove the bolts.
64. Disconnect the output speed sensor (OSS) and position the wire harness aside.
65. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
66. Disconnect the transaxle harness electrical connector and position the wire harness aside.
67. Remove the RH catalytic converter heat shield. Remove one bolt. Remove two nuts.
68. Install the LH engine lifting eye.
69. Install the RH engine lifting eye.
70. Using the special tools, support the engine.
71. Remove the two RH engine support insulator-to-transmission bolts.
72. Remove the LH engine support insulator-to-subframe nut.
73. Remove the RH engine support insulator through bolt.
74. Remove the transmission-to-engine bolts. Remove five bolts. Remove one stud bolt.
75. Separate the engine (6007) from the transmission.

Scheme 460

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Scheme 527

Scheme 528

1. Remove the accessory drive belt.
2. Disconnect the generator electrical connectors.
3. Remove the generator support bracket. Remove the nut. Remove the bolt.
4. Remove the generator. Remove the stud bolt.
5. Remove the accessory drive belt idler pulley. Remove the bolt.
6. Remove the accessory drive belt tensioner. Remove the bolt.
7. Remove the support bracket. Remove the nut. Remove the bolt.
8. Remove the power steering pump and bracket assembly. Remove two nuts. Remove one bolt.
9. Disconnect the A/C high pressure cutoff switch electrical connector.
10. Disconnect the A/C compressor clutch coil electrical connector.
11. Disconnect the oxygen sensor electrical connector and separate the connector ends from the bracket.
12. Remove the A/C compressor. Remove the four bolts.
13. Remove the A/C compressor mounting bracket. Remove the four bolts.
14. Remove the water pump pulley. Remove the four bolts.
15. Disconnect the crankshaft position sensor (CKP) electrical connector.
16. Remove the exhaust gas recirculation (EGR) tube and sensor. Disconnect the electrical connector. Loosen the two compression nuts.
17. Disconnect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors.
18. Remove the pin-type retainer and position the wire harness aside.
19. Disconnect the vacuum tube from the secondary air injection valve.
20. Remove the upper intake manifold support bracket. Remove the bolt. Remove the nut.
21. Disconnect the EGR valve vacuum tube.
22. Disconnect the electronic vacuum regulator (EVR) and the main vacuum harness connections. Disconnect the EVR electrical connector. Disconnect the EVR vacuum tube. Disconnect the vacuum harness connection to the upper intake manifold.
23. Disconnect the oxygen sensor electrical connector and separate it from the bracket.
24. Disconnect the secondary air injection control solenoid. Disconnect the electrical connector. Disconnect the vacuum tubes.
25. Disconnect the positive crankcase ventilation (PCV) valve.
26. Remove the upper intake manifold. Remove the four bolts.
27. Disconnect the Camshaft Position Sensor (CMP), Engine Coolant Temperature (ECT), Water Temperature Sensor (WTS) and the oil pressure sensor electrical connectors.
28. Separate the wire harness from the engine. Remove the pin-type retainers.
29. Disconnect the fuel injectors and remove the engine control sensor wiring harness.
30. Disconnect and remove the LH spark plug wires.
31. Remove the oil level indicator and tube assembly. Remove the nut.
32. Remove the LH exhaust manifold. Remove four bolts. Remove two stud bolts.
33. Remove and discard the LH exhaust manifold gasket.
34. Disconnect and remove the RH spark plug wires.
35. Remove the RH exhaust manifold heat shield. Remove the three bolts.
36. Remove the RH exhaust manifold. Remove the six bolts.
37. Remove and discard the RH exhaust manifold gasket.
38. Remove the RH valve rocker arm cover. Remove three stud bolts. Remove five bolts.
39. Remove the LH valve rocker arm cover. Remove six stud bolts. Remove two bolts.
40. Remove the rocker arms and push rods.
41. Remove the lower intake manifold. Remove the eight bolts.
42. Remove and discard the lower intake manifold gaskets.
43. Remove the crankshaft pulley. Remove the four bolts.
44. Remove the crankshaft damper bolt.
45. Remove the crankshaft position (CKP) sensor.
46. Using the special tool, remove the crankshaft damper.
47. Remove the oil filter.
48. Remove the valve tappet guide plate retainer. Remove the two bolts.
49. Remove the valve tappet guide plates.
50. Remove the valve tappets.
51. Remove the camshaft synchronizer. Refer to «CAMSHAFT SYNCHRONIZER»(ref-142370-S40368237492002102100000) .
52. Remove the oil pan. Remove the 16 bolts.
53. Remove and discard the oil pan gasket.
54. Remove the engine front cover and bolts.
55. Remove the engine front cover and the engine front cover gasket.
56. Remove the RH cylinder head. Remove the eight bolts.
57. Remove the LH cylinder head. Remove the eight bolts.
58. Remove and discard both cylinder head gaskets.
59. Align the timing marks.
60. Remove the camshaft sprocket bolt.
61. Remove the timing sprockets and the timing chain as an assembly.
62. Remove the camshaft thrust plate. Remove the bolts.
63. Remove the camshaft.
64. If required, remove the camshaft bearings.
65. Remove the oil pump. Remove the bolt.
66. Remove the piston and connecting rod assemblies one at a time. Remove the connecting rod nuts in pairs. Remove the connecting rod cap. Remove the piston and connecting rod assembly.
67. Remove the eight main bearing cap bolts.
68. Remove the main bearing caps.
69. Remove the lower crankshaft main bearings.
70. Remove the crankshaft rear oil seal.
71. Remove the crankshaft.
72. Remove the upper crankshaft main bearings.
73. Clean all mating and sealing surfaces of old gasket material and debris.

Scheme 529

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Scheme 596

Scheme 597

Scheme 598

1. Remove the bolts and the flywheel.
2. Mount the engine on a suitable engine stand.
3. Remove the accessory drive belt.
4. Remove the generator support bracket. Remove the nut. Remove the bolt.
5. Remove the bolts and the generator.
6. Remove the bolts and the accessory drive belt tensioner.
7. Remove the support bracket. Remove the nut. Remove the bolt.
8. Remove the bolts and the front end accessory drive bracket assembly.
9. Disconnect the A/C high pressure cutoff switch electrical connector.
10. Disconnect the A/C compressor clutch coil electrical connector.
11. Disconnect the oxygen sensor electrical connector and separate the connector ends from the bracket.
12. Remove the bolts and the A/C compressor.
13. Remove the bolts and the A/C compressor mounting bracket.
14. Remove the bolts and the water pump pulley.
15. Disconnect the crankshaft position sensor (CKP) electrical connector.
16. Remove the Exhaust Gas Recirculation (EGR) tube and sensor. Disconnect the electrical connector. Loosen the two compression nuts.
17. Disconnect the Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors.
18. Remove the pin-type retainer and position the wire harness aside.
19. Remove the upper intake manifold support bracket. Remove the bolt. Remove the nut.
20. Disconnect the EGR valve vacuum tube.
21. Disconnect the EGR vacuum regulator solenoid electrical and vacuum hose connections and the main vacuum harness connection.
22. Disconnect the oxygen sensor electrical connector and separate it from the bracket.
23. Disconnect the Positive Crankcase Ventilation (PCV) valve.
24. Disconnect the spark plug holder and the radio suppressor.
25. Remove the bolts and the upper intake manifold.
26. Disconnect the Camshaft Position Sensor (CMP), Engine Coolant Temperature (ECT), Water Temperature Sensor (WTS) and the oil pressure sensor electrical connectors.
27. Separate the wire harness from the engine. Remove the pin-type retainers.
28. Disconnect the Fuel Injection Pressure (IPR) sensor electrical and vacuum connectors.
29. Disconnect the fuel injectors and remove the engine control sensor wiring harness.
30. Disconnect and remove the LH spark plug wires.
31. Remove the nut and the oil level indicator and tube assembly.
32. Remove the LH exhaust manifold. Remove four bolts. Remove two stud bolts.
33. Remove and discard the LH exhaust manifold gasket.
34. Disconnect and remove the RH spark plug wires.
35. Remove the bolts and the RH exhaust manifold heat shield.
36. Remove the bolts and the RH exhaust manifold.
37. Remove and discard the RH exhaust manifold gasket.
38. Remove the RH valve rocker arm cover. Remove three stud bolts. Remove five bolts.
39. Remove the LH valve rocker arm cover. Remove six stud bolts. Remove two bolts.
40. Remove the rocker arms and push rods.
41. Remove the bolts and the lower intake manifold.
42. Remove and discard the lower intake manifold gaskets.
43. Remove the bolts and the crankshaft pulley.
44. Remove the crankshaft damper bolt.
45. Remove the crankshaft position (CKP) sensor.
46. Using the special tool, remove the crankshaft damper.
47. Remove the oil filter.
48. Remove the bolts and the valve tappet guide plate retainer.
49. Remove the valve tappet guide plates.
50. Remove the valve tappets.
51. Remove the camshaft synchronizer. Refer to «CAMSHAFT SYNCHRONIZER»(ref-142370-S40368237492002102100000) .
52. Remove the bolts and the oil pan.
53. Remove and discard the oil pan gasket.
54. Remove the seven nuts and the oil pan baffle.
55. Remove the bolts and the engine front cover.
56. Remove the engine front cover gasket.
57. Remove the bolts and the RH cylinder head. Discard the bolts.
58. Remove the bolts and the LH cylinder head. Discard the bolts.
59. Remove and discard both cylinder head gaskets.
60. Align the timing marks.
61. Remove the camshaft sprocket bolt.
62. Remove the timing sprockets and the timing chain as an assembly.
63. Remove the bolts and the camshaft thrust plate.
64. Remove the camshaft.
65. If required, remove the camshaft bearings.
66. Remove the bolt and the oil pump.
67. Remove the piston and connecting rod assemblies one at a time. Remove the connecting rod nuts in pairs. Remove the connecting rod cap. Remove the piston and connecting rod assembly.
68. Remove the eight main bearing cap bolts.
69. Remove the main bearing caps.
70. Remove the crankshaft lower main bearings.
71. Remove the crankshaft rear oil seal.
72. Remove the crankshaft.
73. Remove the crankshaft upper main bearings.
74. Clean all mating and sealing surfaces of gasket material and debris.

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

1. Using the special tool, compress the valve spring (6513) and remove the valve spring retainers (6518).
2. Remove the valve springs (6513). For component tests, refer to «VALVE TRAIN ANALYSIS - VALVE SPRINGS»(ref-178685-S32996904482005062000000) .
3. Remove the valve seal (6A517).
4. Remove the valve (6507/6505). For component tests, refer to «VALVE TRAIN ANALYSIS - ENGINE OFF, VALVES AND»(ref-178685-S13715102572005062000000) .
5. To assemble, reverse the disassembly procedure. Lubricate the valve stem and the valve seal with clean engine oil.

Scheme 605

Scheme 606

Scheme 607

1. Remove the piston rings one at a time starting with the top compression ring and finishing with the lower oil control ring.
2. Using the special tool, press the piston pin (6135) out of the piston and connecting rod assembly.
3. Remove the connecting rod (6205) from the piston (6110).
4. Clean and inspect the piston and the connecting rod.

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Using the special tool, press the piston pin into the piston and the connecting rod.
3. Install the second oil control ring.
4. Install the oil control spacer ring.
5. Install the first oil control ring.
6. Install the second compression ring.
7. Install the top compression ring.
8. Check the piston ring end gap and ring-to-groove side clearance. Refer to «PISTON - RING END GAP»(ref-178685-S37897000152005062000000) or «PISTON - RING-TO-GROOVE CLEARANCE»(ref-178685-S09482181052005062000000) .

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Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

1. Install the upper crankshaft main bearings (6333).
2. Position the crankshaft (6303).
3. Install the crankshaft rear oil seal (6701).
4. Apply two dots of gasket marker between the rear bearing cap and the cylinder block (6010).
5. Install the lower crankshaft main bearings (6A338).
6. Install the main bearings caps.
7. Install the main bearing cap bolts in the sequence shown. Tighten the bolts in pairs.
8. If removed, install the camshaft bearings (6261).
9. Install the camshaft.
10. Install the camshaft thrust plate (6269).
11. Inspect the camshaft end play. Refer to «CAMSHAFT - END PLAY, PUSH ROD ENGINES»(ref-178685-S34413810042005062000000) .
12. Align the timing marks.
13. Install the timing chain (6268), the camshaft sprocket (6256) and the crankshaft sprocket (6306) as an assembly.
14. Install the camshaft sprocket bolt.
15. Install the piston and connecting rod assemblies (6100).
16. Install the connecting rod bearings (6211).
17. Install the connecting rod caps (6210) and nuts. Tighten the nuts in pairs.
18. Install the oil pump (6600).
19. Install the valve tappets.
20. Install the valve tappet guide plates (6K512).
21. Install the valve tappet guide plate retainer (6K564).
22. Install new head gaskets (6051).
23. Position the cylinder heads (6049).
24. Install the bolts. Tighten the bolts in the sequence shown in five stages: Stage 1: Tighten The Bolts To 50 Nm (37 Lb-In) Stage 2: Loosen The Bolts One Full Turn Stage 3: Tighten To 30 Nm (22 Lb-Ft) Stage 4: Rotate 85-95 Degrees Stage 5: Rotate An Additional 85-95 Degrees
25. Install the oil filter (6714). Advance the filter one half turn after the gasket contacts the sealing surface.
26. Install a new engine front cover gasket (6020) and the engine front cover (6019).
27. Install the engine front cover and water pump assembly. Apply pipe sealant with Teflon® to the bolts indicated. Install the bolts.
28. Apply four beads of gasket maker as shown.
29. Position the oil pan gasket (6710).
30. Position the oil pan (6675) and hand-start the bolts.
31. Install the bolts. Tighten the bolts in four stages: Stage 1: Tighten The Four Corner Bolts To 12 Nm (9 Lb-In) Stage 2: Tighten The Remaining Bolts To 12 Nm (9 Lb-In) Stage 3: Loosen All The Bolts One Turn Stage 4: Tighten All The Bolts To 12 Nm (9 Lb-In)
32. Install the camshaft synchronizer. Refer to «CAMSHAFT SYNCHRONIZER (3.0L OHV)»(ref-142370-S40368237492002102100000) .
33. Apply four beads of silicone gasket and sealant.
34. Position the intake manifold gaskets (9439) and end seals.
35. Install the lower intake manifold (9424). Tighten the bolts in two stages: Stage 1: Tighten To 15 Nm (11 Lb-Ft) Stage 2: Tighten To 32 Nm (24 Lb-Ft)
36. Install the push rods (6565) and the rocker arms (6564). Install the push rods. Install the rocker arms. Tighten the bolts in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 32 Nm (24 Lb-Ft)
37. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
38. If removed, install the valve cover gaskets (6584).
39. Install the LH valve rocker arm cover (6582). Install the two bolts. Install the six stud bolts.
40. Install the RH valve rocker arm cover. Install the five bolts. Install the three stud bolts.
41. Position a new exhaust manifold gasket and install the RH exhaust manifold.
42. Install the bolts. Tighten the bolts in the sequence shown, in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 22 Nm (16 Lb-Ft)
43. Install the RH exhaust manifold heat shield. Install the bolts.
44. Position and connect the RH spark plug wires.
45. Position a new exhaust manifold gasket (9448) and install the LH exhaust manifold.
46. Install the four bolts and two stud bolts. Tighten the bolts in sequence in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 22 Nm (16 Lb-Ft)
47. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
48. Install the oil level indicator and tube. Install the nut.
49. Position and connect the LH spark plug wires.
50. Position the engine control sensor wiring harness and connect the fuel injectors electrical connectors.
51. Position the wire harness along the cylinder block. Install the pin-type retainers.
52. Connect the camshaft position (CMP) sensor, engine coolant temperature sensor (ECT), water temperature sensor (WTS) and the oil pressure sensor electrical connectors.
53. Inspect the upper intake manifold gasket. Install new if required.
54. Install the upper intake manifold. Tighten the bolts in the sequence shown in two stages: Stage 1: Tighten Hand Tight Stage 2: Tighten To 10 Nm (89 Lb-Ft)
55. Connect the Positive Crankcase Ventilation (PCV) valve.
56. Connect the secondary air injection control solenoid. Connect the electrical connector. Connect the vacuum tube.
57. Install and connect the oxygen sensor electrical connector.
58. Connect the electronic vacuum regulator (EVR) and main vacuum harness connections. Connect the vacuum harness to the upper intake manifold. Connect the EVR vacuum tube. Connect the EVR electrical connector.
59. Connect the EGR valve vacuum tube.
60. Install the upper intake manifold support bracket. Install the bolt. Install the nut.
61. Connect the vacuum tube to the secondary air injection valve.
62. Position the wire harness and install the pin-type retainers.
63. Connect the Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors.
64. Install the EGR tube. Connect the electrical connector. Tighten the two compression nuts.
65. Install the crankshaft damper and crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
66. Install the Crankshaft Position (CKP) sensor (6C315).
67. Connect the CKP sensor electrical connector.
68. Install the water pump pulley. Install the bolts.
69. Install the A/C compressor mounting bracket. Install the bolts.
70. Install the A/C compressor. Install the bolts.
71. Install the wire harness connectors on the bracket and connect the oxygen sensor electrical connector.
72. Connect the A/C compressor clutch coil electrical connector.
73. Connect the A/C high pressure cutoff switch electrical connector.
74. Install the power steering pump and bracket assembly. Install the nuts. Install the bolt.
75. Install the support bracket. Install the nut. Install the bolt.
76. Install the accessory drive belt tensioner. Install the bolt.
77. Install the accessory drive belt idler pulley. Install the bolt.
78. Install the generator. Install the stud bolt.
79. Install the generator support bracket. Install the nut. Install the bolt.
80. Connect the generator electrical connectors.
81. Install the accessory drive belt.

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

1. Install the crankshaft upper main bearings (6333).
2. Position the crankshaft (6303).
3. Install the crankshaft rear oil seal (6701).
4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block (6010).
5. Install the crankshaft lower main bearings (6A338).
6. Install the main bearing caps.
7. Install the main bearing cap bolts in the sequence shown. Tighten the bolts in pairs.
8. If removed, install the camshaft bearings (6261).
9. Install the camshaft.
10. Install the camshaft thrust plate (6269).
11. Inspect the camshaft end play. Refer to «CAMSHAFT -- END PLAY, PUSH ROD ENGINES»(ref-178685-S34413810042005062000000) .
12. Align the timing marks.
13. Install the timing chain (6268), the camshaft sprocket (6256) and the crankshaft sprocket (6306) as an assembly.
14. Install the camshaft sprocket bolt.
15. Install the piston and connecting rod assemblies (6100).
16. Install the connecting rod bearings (6211).
17. Install the connecting rod caps (6210) and nuts. Tighten the nuts in pairs.
18. Install the oil pump (6600).
19. Install the valve tappets.
20. Install the valve tappet guide plates (6K512).
21. Install the valve tappet guide plate retainer (6K564).
22. Install new head gaskets (6051).
23. Position the cylinder heads (6049).
24. Install new bolts. Tighten the bolts in the sequence shown in five stages: Stage 1: Tighten The Bolts To 50 Nm (37 Lb-In) Stage 2: Loosen The Bolts One Full Turn Stage 3: Tighten To 30 Nm (22 Lb-Ft) Stage 4: Rotate 85-95 Degrees Stage 5: Rotate An Additional 85-95 Degrees
25. Install the oil filter (6714). Advance the filter one half turn after the gasket contacts the sealing surface.
26. Install a new engine front cover gasket (6020) and the engine front cover (6019).
27. Install the engine front cover and water pump assembly. Apply pipe sealant with Teflon® to the bolts indicated. Install the bolts.
28. Install the oil pan baffle and the seven retaining nuts.
29. Apply four beads of gasket maker as shown.
30. Position the oil pan gasket onto the oil pan.
31. Position the oil pan (6675) and hand-start the bolts.
32. Install the bolts. Tighten the bolts in four stages: Stage 1: Tighten The Four Corner Bolts To 12 Nm (9 Lb-In) Stage 2: Tighten The Remaining Bolts To 12 Nm (9 Lb-In) Stage 3: Loosen All The Bolts One Turn Stage 4: Tighten All The Bolts To 12 Nm (9 Lb-In)
33. Install the camshaft synchronizer. Refer to «CAMSHAFT SYNCHRONIZER (3.0L OHV)»(ref-142370-S40368237492002102100000) .
34. Apply four beads of silicone gasket and sealant.
35. Position the intake manifold gaskets (9439) and end seals.
36. Install the lower intake manifold (9424). Tighten the bolts in two stages: Stage 1: Tighten To 15 Nm (11 Lb-Ft) Stage 2: Tighten To 32 Nm (24 Lb-Ft)
37. Install the push rods (6565) and the rocker arms (6564). Install the push rods. Install the rocker arms. Tighten the bolts in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 32 Nm (24 Lb-Ft)
38. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
39. If removed, install the valve cover gaskets (6584).
40. Install the LH valve rocker arm cover (6582). Install the two bolts. Install the six stud bolts.
41. Install the RH valve rocker arm cover. Install the five bolts. Install the three stud bolts.
42. Position a new exhaust manifold gasket and install the RH exhaust manifold.
43. Install the bolts. Tighten the bolts in the sequence shown, in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 22 Nm (16 Lb-Ft)
44. Install the RH exhaust manifold heat shield.
45. Position and connect the RH spark plug wires.
46. Position a new exhaust manifold gasket (9448) and install the LH exhaust manifold.
47. Install the four bolts and two stud bolts. Tighten the bolts in sequence in two stages: Stage 1: Tighten To 10 Nm (89 Lb-In) Stage 2: Tighten To 22 Nm (16 Lb-Ft)
48. Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
49. Install the oil level indicator and tube. Install the nut.
50. Position and connect the LH spark plug wires.
51. Position the engine control sensor wiring harness and connect the fuel injectors electrical connectors.
52. Connect the fuel injection pressure (IPR) sensor electrical and vacuum connectors.
53. Position the wire harness along the cylinder block. Install the pin-type retainers.
54. Connect the camshaft position (CMP) sensor, engine coolant temperature sensor (ECT), water temperature sensor (WTS) and the oil pressure sensor electrical connectors.
55. Inspect the upper intake manifold gasket. Install new if required.
56. Install the upper intake manifold. Tighten the bolts in the sequence shown in two stages: Stage 1: Tighten Hand Tight Stage 2: Tighten To 10 Nm (89 Lb-Ft)
57. Connect the spark plug holder and the radio suppressor.
58. Connect the Positive Crankcase Ventilation (PCV) valve.
59. Install and connect the oxygen sensor electrical connector.
60. Connect the EGR vacuum regulator solenoid electrical and vacuum hose connectors, and main vacuum harness connections.
61. Connect the EGR valve vacuum hose.
62. Install the upper intake manifold support bracket. Install the bolt. Install the nut.
63. Position the wire harness and install the pin-type retainers.
64. Connect the Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors.
65. Install the EGR tube. Connect the electrical connector. Tighten the two compression nuts.
66. Install the crankshaft damper and crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-178530-S34684766492005061600000) .
67. Install the Crankshaft Position (CKP) sensor (6C315).
68. Connect the CKP sensor electrical connector.
69. Install the water pump pulley. Install the bolts.
70. Install the A/C compressor mounting bracket. Install the bolts.
71. Install the A/C compressor. Install the bolts.
72. Install the wire harness connectors on the bracket and connect the oxygen sensor electrical connector.
73. Connect the A/C compressor clutch coil electrical connector.
74. Connect the A/C high pressure cutoff switch electrical connector.
75. Install the front end accessory drive bracket assembly.
76. Install the support bracket. Install the nut. Install the bolt.
77. Install the accessory drive belt tensioner. Install the bolts.
78. Install the generator and the bolts.
79. Install the generator support bracket. Install the nut. Install the bolt.
80. Install the accessory drive belt.
81. Remove the engine from the stand.
82. Install the flywheel and the bolts.

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

1. Install the flywheel.
2. Position the engine on the subframe and transmission assembly.
3. Install the transmission to engine bolts. Install five bolts. Install one stud bolt.
4. Install the RH engine support insulator through bolt.
5. Install the LH engine support insulator-to-subframe nut.
6. Install the two RH engine support insulator-to-transmission bolts.
7. Disconnect the engine lift equipment and position it aside.
8. Remove the RH engine lifting eye.
9. Remove the LH engine lifting eye.
10. Install the secondary air injection hose.
11. Install the RH catalytic converter heat shield. Install the two nuts. Position the ground strap and install the bolt.
12. Position the 42-pin connector on the bracket and connect the transaxle harness electrical connector.
13. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
14. Connect the output speed sensor (OSS) electrical connector.
15. Install the ignition coil. Install the bolts.
16. Connect the ignition coil electrical connector.
17. Connect the ignition coil. Connect the spark plug wires.
18. Install the secondary air injection valve and bracket. Install the nuts.
19. Connect the secondary air injection valve vacuum tube.
20. Connect the control valve solenoid to the bracket.
21. Install the LH secondary air injection tube. Tighten the compression nuts.
22. Connect the power steering pressure line to the power steering pump.
23. Install the power steering pressure line bracket. Install the nut.
24. Install the power steering pressure line bracket. Install the nut.
25. Using the special tool, raise the engine, transmission and subframe in to the vehicle.
26. Install the four front subframe-to-body bolts.
27. Lower the special tool and position it aside.
28. Install the LH and RH half shafts to the steering knuckles.
29. Connect the LH and RH tie rod ends to the steering knuckles.
30. Connect the LH and RH lower control arms to the steering knuckles.
31. Connect the LH and RH stabilizer links to the stabilizer bar.
32. Install the four torque converter nuts.
33. Install the engine rear plate.
34. Install the starter motor.
35. Connect the starter motor electrical connectors. Install the nuts.
36. Install the starter motor electrical connector cover.
37. Connect the auxiliary oil cooler assembly. Connect the transmission oil cooler hose, if equipped. Connect the power steering return hose.
38. Connect the wire harness electrical connector.
39. Connect the transmission oil cooler hose.
40. Connect the lower radiator hose to the radiator and the degas bottle supply hose.
41. Install the radiator support bracket.
42. Connect the lower radiator hose to the water pump.
43. Connect the A/C discharge tube. Install the nut.
44. Install the front wheels.
45. Install the catalytic converters and Y-pipe assemblies.
46. Connect the catalyst monitor sensor electrical connector.
47. Connect the catalyst monitor sensor electrical connector.
48. Install the valance panel. Install the three screws. Install the 9 pin-type retainers.
49. Lower the vehicle.
50. Connect the Powertrain Control Module (PCM) electrical connector. Tighten the bolt.
51. Connect the Evaporative Emissions (EVAP) canister purge valve electrical connector.
52. Connect the ground electrical connectors. Install the bolt.
53. Connect the heater water hose.
54. Connect the degas hose to the degas bottle.
55. Install the engine roll restrictor. Install the bolts.
56. Install the engine roll restrictor brace. Install the nuts.
57. Connect the fuel supply hose. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
58. Connect the A/C suction tube to the accumulator drier.
59. Connect the generator electrical connectors.
60. Connect the power steering return hose.
61. Connect the ground strap electrical connector. Install the nut.
62. Connect the upper radiator hose and heater water hose to the thermostat housing.
63. Connect the Transmission Range (TR) sensor and the 42-pin electrical connector. Tighten the bolt.
64. Install the manual control lever cable.
65. Connect the manual control lever cable to the manual control lever. Install the nut.
66. Connect the chassis vacuum hose.
67. Install the accelerator cable bracket. Install the bolts.
68. Connect the accelerator cable, speed control cable and throttle return spring.
69. Install the snow shield. Install the pin-type retainers.
70. Connect the steering column to the steering gear input shaft. Tighten the pinch bolt.
71. Install the steering column input shaft coupling boot. Install the three nuts.
72. Install the Engine Air Cleaner (ACL) (9600) and the engine air cleaner outlet tube (9B659).
73. Install the cowl extension and cowl vent screen.
74. Install the battery and connect the battery ground cable.
75. Fill the engine with clean engine oil.
76. Fill and bleed the engine cooling system. Refer to «BLEEDING»(ref-139103-S23703246542002042500000) .
77. Charge the A/C system. Refer to «REFRIGERANT SYSTEM CHARGING»(ref-178710-S24401265432005062100000) .
78. Fill and bleed the power steering system. Refer to «POWER STEERING SYSTEM FILLING»(ref-178350-S42156665562005061400000) .
79. Inspect the engine and cooling system for leaks.

Scheme 826

Scheme 827

Scheme 828

Scheme 829

Scheme 830

Scheme 831

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

Scheme 847

Scheme 848

Scheme 849

Scheme 850

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

Scheme 856

Scheme 857

Scheme 858

Scheme 859

Scheme 860

Scheme 861

Scheme 862

Scheme 863

Scheme 864

Scheme 865

Scheme 866

Scheme 867

Scheme 868

Scheme 869

Scheme 870

Scheme 871

Scheme 872

Scheme 873

Scheme 874

Scheme 875

Scheme 876

Scheme 877

Scheme 878

Scheme 879

Scheme 880

Scheme 881

Scheme 882

Scheme 883

Scheme 884

Scheme 885

Scheme 886

Scheme 887

Scheme 888

Scheme 889

1. Position the engine on the subframe and transmission assembly.
2. Install the transmission to engine bolts. Install five bolts. Install one stud bolt.
3. Install the RH engine support insulator through bolt.
4. Install the LH engine support insulator-to-subframe nut.
5. Install the two RH engine support insulator-to-transmission bolts.
6. Disconnect the engine lift equipment and position it aside.
7. Remove the RH engine lifting eye.
8. Remove the LH engine lifting eye.
9. Install the RH catalytic converter heat shield. Install the two nuts. Position the ground strap and install the bolt.
10. Position the 42-pin connector on the bracket and connect the transaxle harness electrical connector.
11. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
12. Connect the output speed sensor (OSS) electrical connector.
13. Install the ignition coil. Install the bolts.
14. Connect the ignition coil electrical connector.
15. Connect the ignition coil. Connect the spark plug wires.
16. Using the special tool, install a new O-ring seal on the pressure line fitting.
17. Connect the power steering pressure line to the power steering pump.
18. Install the power steering pressure line bracket. Install the nut.
19. Install the power steering pressure line bracket. Install the nut.
20. Using the special tool, raise the engine, transmission and subframe in to the vehicle.
21. Install the four front subframe-to-body bolts.
22. Lower the special tool and position it aside.
23. Install the LH and RH half shafts to the steering knuckles.
24. Connect the LH and RH tie rod ends to the steering knuckles.
25. Connect the LH and RH lower control arms to the steering knuckles.
26. Connect the LH and RH stabilizer links to the stabilizer bar.
27. Install the four torque converter nuts.
28. Install the engine rear plate.
29. Install the starter motor.
30. Connect the starter motor electrical connectors. Install the nuts.
31. Install the starter motor electrical connector cover.
32. Connect the auxiliary oil cooler assembly. Connect the transmission oil cooler hose, if equipped. Connect the power steering return hose.
33. Connect the wire harness electrical connector.
34. Connect the transmission oil cooler hose.
35. Connect the lower radiator hose to the radiator and the degas bottle supply hose.
36. Install the radiator support bracket.
37. Connect the lower radiator hose to the water pump.
38. Connect the A/C discharge tube. Install the nut.
39. Install the front wheels.
40. Install the catalytic converters and Y-pipe assemblies.
41. Connect the catalyst monitor sensor electrical connector.
42. Connect the catalyst monitor sensor electrical connector.
43. Install the valance panel. Install the three screws. Install the nine pin-type retainers.
44. Lower the vehicle.
45. Connect the powertrain control module (PCM) electrical connector. Tighten the bolt.
46. Connect the Evaporative Emissions (EVAP) canister purge valve electrical connector.
47. Connect the ground electrical connectors. Install the bolt.
48. Connect the heater water hose.
49. Connect the degas hose to the degas bottle.
50. Install the engine roll restrictor. Install the bolts.
51. Install the engine roll restrictor brace. Install the nuts.
52. Connect the fuel supply hose. Refer to «FUEL LINE CONNECTOR»(ref-142370-S39102991382002073100000) .
53. Connect the A/C suction tube to the accumulator drier.
54. Install the alternator cable bracket bolt.
55. Connect the generator electrical connectors.
56. Connect the power steering return hose.
57. Connect the ground strap electrical connector. Install the nut.
58. Connect the upper radiator hose and heater water hose to the thermostat housing.
59. Connect the transmission range (TR) sensor and the 42-pin electrical connectors. Tighten the bolt.
60. Install the manual control lever cable.
61. Connect the manual control lever cable to the manual control lever. Install the nut.
62. Connect the chassis vacuum hose.
63. Install the accelerator cable bracket. Install the bolts.
64. Connect the accelerator cable, speed control cable and throttle return spring.
65. Install the snow shield. Install the pin-type retainers.
66. Connect the steering column to the steering gear input shaft. Tighten the pinch bolt.
67. Install the steering column input shaft coupling boot. Install the three nuts.
68. Install the Engine Air Cleaner (ACL) (9600) and the engine air cleaner outlet tube (9B659).
69. Install the cowl extension and cowl vent screen.
70. Install the battery and connect the battery ground cable.
71. Fill the engine with clean engine oil.
72. Fill and bleed the engine cooling system. Refer to «BLEEDING»(ref-139103-S23703246542002042500000) .
73. Charge the A/C system. Refer to «REFRIGERANT SYSTEM CHARGING»(ref-178710-S24401265432005062100000) .
74. Fill and bleed the power steering system. Refer to «POWER STEERING SYSTEM FILLING»(ref-178350-S42156665562005061400000) .
75. Inspect the engine and cooling system for leaks.