Contents Wiring diagrams Section: Mechanical All sections

Engine - 3.5L: Overhaul Mercury Sable V

Mechanical 5 illustrations ~3841 words

DISASSEMBLY

All cylinder heads

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

  1. Using the Valve Spring Compressors, remove the keys, retainer and spring.
  2. Remove the valve from the cylinder head.
  3. Remove and discard the valve stem seal.
  4. Repeat the above steps for each valve.
  5. Remove and discard the Cylinder Head Temperature (CHT) sensor.

ASSEMBLY

All cylinder heads

  1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
  2. Install the valve.
  3. Using the Valve Spring Compressors, install the valve spring, retainer and key.
  4. Repeat the above steps for each valve.
  5. Install a new CHT sensor. Tighten to 10 Nm (89 lb-in).

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Camshaft Alignment Tool 303-1248 Engine Lifting Bracket 303-1245 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Rear Seal 303-1250 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

ItemSpecification
Motorcraft High Performance Engine RTV Silicone TA-357WSE-M4G323-A6
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

Scheme 17

Scheme 17
ItemPart NumberDescription
112C508Engine control harness
29S455Upper intake manifold
39J444Upper intake manifold long support bracket (early build engines)
49F797Fuel rail
59J444Upper intake manifold short support bracket
69K461Lower intake manifold
78A856Thermostat housing
89N271Coolant tube
99N271Knock sensor (KS)
106010Cylinder block

Scheme 18

Scheme 18
ItemPart NumberDescription
16A0003Engine mount bracket
2W701512Crankshaft pulley bolt
3N806165Crankshaft pulley washer
46316Crankshaft pulley
56700Crankshaft front seal
66C086Engine front cover
76268Timing chain
86306Crankshaft timing sprocket
96K254Primary timing chain tensioner
106K255Primary timing chain tensioner arm
116B274LH lower primary timing chain guide
126M256RH primary timing chain guide
136K297LH upper primary timing chain guide
148501Coolant pump
156010Cylinder block

Scheme 19

Scheme 19
ItemPart NumberDescription
16675Oil pan
26622Oil pump screen and pickup tube
36621Oil pump
46010Cylinder block
56D327Crankshaft rear seal retainer
612A227Crankshaft sensor ring
76375Flexplate
86881Oil filter adapter
99278Engine oil pressure (EOP) switch

Scheme 20

Scheme 20
ItemPart NumberDescription
16083LH cylinder head gasket
26C261LH variable camshaft timing (VCT) housing
3W12244LH exhaust manifold stud (6 required)
46500Valve tappet (32 required)
56050LH cylinder head
66279LH camshaft bolt (2 required)
7W710738LH exhaust camshaft sprocket washer
86C524LH VCT assembly
96256LH exhaust camshaft sprocket
106C256LH secondary timing chain
116A258LH camshaft cap (8 required)
126A505LH valve cover
136A267LH intake camshaft
146A269LH exhaust camshaft
156C271LH secondary timing chain tensioner

Scheme 21

Scheme 21
ItemPart NumberDescription
1W712244RH exhaust manifold stud (6 required)
26051RH cylinder head gasket
36G004Cylinder head temperature (CHT) sensor
414B485CHT sensor jumper harness
56B288Camshaft position sensor (2 required)
66049RH cylinder head
717A084Engine lift eye
86C260RH variable camshaft timing (VCT) housing
96279RH camshaft bolt (2 required)
10W710738RH exhaust camshaft sprocket washer
116256RH exhaust camshaft sprocket
126C524RH VCT assembly
136C256RH secondary timing chain
146A266RH intake camshaft
156A268RH exhaust camshaft
1612405Spark plug (6 required)
176A258RH camshaft cap (8 required)
186582RH valve cover
1912A375Coil-on-plug (6 required)
206C270RH secondary timing chain tensioner
CAUTIONDuring engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

All vehicles

  1. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
  2. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  3. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  4. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  5. Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
  6. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
  7. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
  8. Align the oil pan to the cylinder block and A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
  9. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
  10. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown. Tighten the large bolts (1-14) to 20 Nm (15 lb-ft). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
  11. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
  12. Install the coolant pump and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  13. Install the knock sensor (KS) and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
  14. Using new O-ring seals, install the coolant tube.
  15. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  16. Install the bolt. Tighten to 10 Nm (89 lb-in).
  17. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
  18. Install the bolt. Tighten to 10 Nm (89 lb-in).
  19. Position the crankshaft dowel pin in the 9 o'clock position.
  20. Install the valve tappets.
  21. Position the camshafts onto the RH cylinder head in the neutral position as shown.
  22. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  23. Position the camshafts onto the LH cylinder head in the neutral position as shown.
  24. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  25. Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to «Valve Clearance Check»(ref-293494-S04414098612008080700000) .
  26. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  27. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  28. Rotate the RH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
  29. Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  30. Position the RH secondary timing assembly onto the camshafts.
  31. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  32. Remove the lockpin from the RH secondary timing chain tensioner.
  33. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  34. Rotate the LH camshafts to the TDC position and install the special tool on the flats of the camshafts.
  35. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  36. Position the LH secondary timing assembly onto the camshafts.
  37. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  38. Remove the lockpin from the LH secondary timing chain tensioner.
  39. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  40. Install the crankshaft timing chain sprocket.
  41. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  42. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  43. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  44. Install the primary timing chain tensioner arm.
  45. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  46. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
  47. As a post-check, verify correct alignment of all timing marks.
  48. Install new VCT housing seals.
  49. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  50. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  51. Install the special tools.
  52. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  53. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
  54. Remove the special tools (alignment pins).
  55. Install the engine mount bracket and the 3 bolts.
  56. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  57. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
  58. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  59. Using the special tools, install a new crankshaft front seal.
  60. Using the special tools, install the crankshaft pulley.
  61. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
  62. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
  63. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  65. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  66. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  67. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
  68. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
  69. Install the EOP switch. Tighten to 18 Nm (13 lb-ft).
  70. Install the crankshaft position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
  71. Install LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  72. Install and connect the CHT sensor jumper harness.
  73. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  74. Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  75. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
  76. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
  77. Install the coolant bypass hose to the thermostat housing.
  78. Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
  79. Install the upper intake manifold short support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  80. If equipped, install the upper intake long support manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
  81. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
  82. Install the cover and the pin-type retainer.
  83. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
  84. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
  85. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  86. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  87. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  88. Using a new gasket, install the RH catalytic converter and the 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  89. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
  90. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
  91. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
  92. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
  93. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
  94. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
  95. Install the power steering pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
  96. Install the PSP tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
  97. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
  98. Install the generator, the bolt and the nut. Tighten to 48 Nm (35 lb-ft).
  99. Position the wiring harness onto the engine.
  100. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
  101. Connect the generator electrical connector.
  102. Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
  103. Connect the A/C compressor electrical connector. Attach the A/C compressor wiring harness retainer.
  104. Connect the CKP sensor electrical connector.
  105. Install the wiring harness grommet.
  106. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
  107. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
  108. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  109. Connect the LH camshaft VCT solenoid electrical connector.
  110. Connect the 3 LH coil-on-plug electrical connectors.
  111. Connect the LH HO2S electrical connector.
  112. Connect the LH catalyst monitor sensor electrical connector.
  113. Connect the LH CMP sensor electrical connector.
  114. Connect the CHT sensor electrical connector.
  115. Connect the 6 fuel injector electrical connectors (3 shown).
  116. Install the ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
  117. Connect the KS electrical connector.
  118. Connect the RH CMP sensor electrical connector.
  119. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  120. If equipped, connect the heated PCV valve electrical connector.
  121. Connect the 3 RH coil-on-plug electrical connectors.
  122. Connect the RH VCT solenoid electrical connector.
  123. Connect the RH HO2S electrical connector.
  124. Connect the RH catalyst monitor sensor electrical connector.
  125. Connect the PSP switch electrical connector.
  126. Connect the fuel efficient power steering system solenoid electrical connector.
  127. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  128. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer. Tighten to 6 Nm (53 lb-in).
  129. Install the upper intake manifold short support bracket and the 2 bolts (1 shown). Tighten to 10 Nm (89 lb-in).
  130. If equipped, install the upper intake manifold long support bracket and the 2 bolts (1 shown). Tighten the upper bolt 10 Nm (89 lb-in). Tighten the lower bolt 24 Nm (18 lb-ft).
  131. Attach the wiring harness retainers to the upper intake manifold.
  132. Connect the throttle body (TB) electrical connector.
  133. Connect the PCV hose to the PCV valve.
  134. If equipped, connect the heated PCV electrical connector.
  135. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
  136. If equipped, connect the block heater electrical connector and install the heat shield.
  137. Install the special tool on the LH cylinder head.
  138. Using the special tools, remove the engine from the stand.
  139. Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
  140. Using the special tools, install the new crankshaft rear seal.
  141. Install the crankshaft sensor ring.
  142. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

All vehicles

  1. Using the special tools, align the transaxle to the engine.
  2. Install the 5 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
  3. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
  4. Using the special tools, position the engine and transaxle onto the lift table.
  5. Install the special tools.
  6. Install the starter, the stud bolt and bolt. Tighten to 27 Nm (20 lb-ft).
  7. Connect the wiring harness retainer to the starter motor stud bolt.
  8. Attach the starter wire terminals and install the 2 nuts. Tighten to 12 Nm (9 lb-ft). Tighten to 5 Nm (44 lb-in).
  9. If equipped, install the starter motor solenoid cover.
  10. Raise the engine and transaxle assembly into the vehicle.
  11. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
  12. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
  13. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (15 lb-ft).
  14. Install the transaxle mount bracket and the 4 nuts. Tighten to 80 Nm (59 lb-ft).
  15. Install the transaxle mount through bolt and nut. Tighten to 175 Nm (129 lb-ft).
  16. Position the power transfer unit (PTU) in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
  17. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
  18. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-293504) article.
  19. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  20. Connect the RH catalyst monitor electrical connector.
  21. Install the RH halfshaft support bracket and the 4 bolts. Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft). Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (15 lb-ft).
  22. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
  23. Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts. Tighten to 40 Nm (30 lb-ft).
  24. Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
  25. Install 3 new torque converter bolts. Tighten to 55 Nm (41 lb-ft).
  26. Install the inspection cover and the 2 fasteners.
  27. Connect the transaxle cooling tubes and install the safety clips.
  28. Install the LH halfshaft into the transaxle.
  29. Using the special tool, raise the subframe into the installed position.
  30. Install the 2 front subframe bolts. Tighten to 150 Nm (111 lb-ft).
  31. Position the subframe brackets and install the 4 bolts finger-tight.
  32. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
  33. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
  34. Install new lower ball joint-to-wheel knuckle nuts. Tighten to 115 Nm (85 lb-ft).
  35. Install new tie-rod end nuts. Tighten to 115 Nm (85 lb-ft).
  36. Install new upper stabilizer bar link nuts. Tighten to 55 Nm (41 lb-ft).
  37. Install the new halfshaft nut. Tighten to 350 Nm (258 lb-ft).
  38. Install the 2 engine roll restrictor-to-transaxle bolts. Tighten to 103 Nm (76 lb-ft).
  39. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 25 Nm (18 lb-ft).
  40. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
  41. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  42. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown). Tighten to 70 Nm (52 lb-ft).
  43. Using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
  44. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
  45. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
  46. Connect the transaxle control electrical connector.
  47. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
  48. Connect the hose to the power steering reservoir.
  49. Install the oil level indicator.
  50. Install the ground cable and bolt. Tighten to 12 Nm (9 lb-ft).
  51. Attach the wire to the RH valve cover stud bolt.
  52. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
  53. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
  54. Using a new O-ring seal, install the A/C tube and the nut. Tighten to 15 Nm (11 lb-ft).
  55. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
  56. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 15 Nm (11 lb-ft).
  57. If equipped, attach the engine block heater harness to the radiator support and the power steering tube.
  58. Connect the transaxle control cable to the shift cable bracket and attach the 2 wiring harness pin-type retainers.
  59. Connect the transaxle control cable to the control lever.
  60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  61. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  62. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  63. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  64. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
  65. Connect the engine wiring harness electrical connector.
  66. Install the battery tray and bracket and the nut and bolt. Tighten to 9 Nm (80 lb-in).
  67. Install the 2 lower battery tray bracket bolts. Tighten to 9 Nm (80 lb-in).
  68. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
  69. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
  70. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.
  71. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
  72. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
  73. Connect the power steering cooler tube.
  74. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
  75. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
  76. Fill the engine with clean engine oil.
  77. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
  78. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-293459) article.
  79. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.