Engine - 3.5L: Removal & Installation Mercury Sable V

REMOVAL

All engines

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
2. Disconnect the throttle body (TB) electrical connector.
3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
4. Detach the EVAP tube pin-type retainer from the upper intake manifold.
5. Disconnect the brake booster vacuum hose from the intake manifold.
6. Disconnect the PCV tube from the PCV valve.
7. Disconnect the heated PCV electrical connector.
8. Remove the upper intake manifold long support bracket bolt.
9. Detach the wiring harness retainers from the upper intake manifold.
10. Remove the upper intake manifold short support bracket bolt.
11. Remove the fuel tube bracket bolt.
12. Remove the 6 bolts and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

INSTALLATION

All engines

1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the fuel tube bracket bolt. Tighten to 6 Nm (53 lb-in).
3. Install the upper intake manifold short support bracket bolt. Tighten to 10 Nm (89 lb-in).
4. Attach the wiring harness retainers to the upper intake manifold.
5. Install the upper intake manifold long support bracket bolt. Tighten to 10 Nm (89 lb-in).
6. Connect the heated PCV electrical connector.
7. Connect the PCV tube to the PCV valve.
8. Connect the brake booster vacuum hose to the intake manifold.
9. Connect the EVAP tube to the intake manifold.
10. Attach the EVAP tube pin-type retainer to the upper intake manifold.
11. Connect the TB electrical connector.
12. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.

Scheme 7

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L»(ref-293500) article.
3. Remove the 3 thermostat housing-to-lower intake manifold bolts.
4. Remove the 10 bolts and the lower intake manifold. Remove and discard the intake manifold and thermostat housing gaskets. Clean and inspect all sealing surfaces.

1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the 3 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
3. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.5L»(ref-293500) article.
4. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.

1. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.
2. Remove the oil level indicator.
3. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
4. Detach and disconnect the 2 engine control wiring harness electrical connectors.
5. Detach all of the wiring harness retainers from the LH valve cover stud bolts.
6. Disconnect the 3 LH fuel injector electrical connectors.
7. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
8. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
9. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.

1. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
3. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Connect the 3 LH fuel injector electrical connectors.
5. Attach all of the wiring harness retainers to the LH valve cover stud bolts.
6. Connect and attach the 2 engine control wiring harness electrical connectors.
7. Connect the LH VCT solenoid electrical connector.
8. Install the oil level indicator.
9. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.

All engines

1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.
2. Detach and disconnect the RH catalyst monitor sensor electrical connector.
3. Detach and disconnect the RH heated oxygen sensor (HO2S) electrical connector.
4. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
5. Disconnect the 3 RH fuel injector electrical connectors.
6. Disconnect the heated PCV valve electrical connector.
7. Detach all of the wiring harness retainers from the RH valve cover stud bolts.
8. Remove the nut and the power steering pressure (PSP) tube bracket from the valve cover stud bolt.
9. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket.
10. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
11. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface cleaner.

All engines

1. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
3. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Install the PSP tube bracket on the valve cover stud bolt and install the nut. Tighten to 7 Nm (62 lb-in).
5. Attach all of the wiring harness retainers to the RH valve cover stud bolts.
6. Connect the heated PCV valve electrical connector.
7. Connect the 3 RH fuel injector electrical connectors.
8. Connect the RH VCT electrical connector.
9. Connect the RH HO2S sensor electrical connector.
10. Connect the RH catalyst monitor sensor electrical connector.
11. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-293498) article.

Scheme 8

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
3. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
4. Using the special tool, remove the crankshaft pulley.

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft pulley.
3. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-293494-S23641749392008080700000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

1. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-293494-S23641749392008080700000) .

Scheme 9

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

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50»(ref-293476) article.
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove the flexplate. For additional information, refer to «Flexplate»(ref-293494-S38655527152008080700000) .
3. Remove the crankshaft sensor ring.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.

1. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
2. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
3. Install the crankshaft sensor ring.
4. Install the flexplate. For additional information, refer to «Flexplate»(ref-293494-S38655527152008080700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
4. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
6. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
7. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
8. Remove the nut and the A/C tube-to-receiver/drier. Discard the O-ring seal.
9. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
10. Remove the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-293468) article.
11. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
12. Using the special tool, remove the crankshaft pulley.
13. Using the special tool, remove and discard the crankshaft front seal.
14. Remove the 4 nuts and the Y-pipe-to-catalytic converter nuts. Discard the nuts.
15. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
16. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
17. Disconnect the hose from the power steering reservoir.
18. Remove the RH and LH valve covers. For additional information, refer to «Valve Cover - LH»(ref-293494-S18381259972008080700000) and «Valve Cover - RH»(ref-293494-S28951036752008080700000) .
19. Remove the bolt and the ground cable.
20. Disconnect the fuel efficient power steering system solenoid electrical connector.
21. Disconnect the power steering pressure (PSP) switch electrical connector.
22. Remove the PSP tube bracket-to-power steering pump bolt.
23. Remove the 3 bolts and position aside the power steering pump.
24. Position a floor jack and the special tool under the oil pan.
25. Remove the nut, bolt and engine mount brace.
26. Remove the 4 engine mount nuts.
27. Remove the 3 bolts and the engine mount.
28. Remove the 2 bolts and the engine mount bracket.
29. Remove the 2 engine mount studs.
30. Remove the 2 upper engine mount bracket bolts.
31. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
32. Remove the A/C tube bracket bolt.
33. Remove the A/C tube retaining clamp bolt.
34. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes. Discard the O-ring seals.
35. Using the floor jack, raise the engine slightly.
36. Remove the 22 engine front cover bolts.
37. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.

1. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
2. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
3. Install the special tools.
4. 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.
5. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
6. Remove the special tools (alignment pins).
7. Install the engine mount bracket and lower bolt. Do not tighten at this time.
8. Install the 2 upper engine mount bracket bolts. Do not tighten at this time.
9. 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).
10. Using the floor jack, lower the engine to the installed position.
11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt. Tighten to 15 Nm (11 lb-ft).
12. Install the A/C tube retaining clamp bolt. Tighten to 10 Nm (89 lb-in).
13. Install the A/C tube bracket bolt. Tighten to 10 Nm (89 lb-in).
14. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
15. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
16. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
17. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
18. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (15 lb-ft).
19. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
20. Install the power steering pressure (PSP) tube bracket-to-power steering pump bolt. Tighten to 10 Nm (89 lb-in).
21. Connect the PSP switch electrical connector.
22. Connect the fuel efficient power steering system solenoid electrical connector.
23. Install the ground cable bolt. Tighten to 12 Nm (9 lb-ft).
24. Install the RH and LH valve covers. For additional information, refer to «Valve Cover - LH»(ref-293494-S18381259972008080700000) and «Valve Cover - RH»(ref-293494-S28951036752008080700000) .
25. Connect the hose to the power steering reservoir.
26. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts. Tighten to 40 Nm (30 lb-ft). Attach the exhaust hanger.
27. Install the exhaust Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
28. Using the special tools, install a new crankshaft front seal.
29. Using the special tools, install the crankshaft pulley.
30. 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.
31. Install the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-293468) article.
32. Connect the power steering cooler tube.
33. Install a new O-ring seal and the A/C tube-to-receiver/drier and the nut. Tighten to 15 Nm (11 lb-ft).
34. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
35. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
36. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
37. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
38. Install the engine air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
39. Fill the engine with clean engine oil.
40. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-293459) article.
41. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-293494-S36456647872008080700000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 bolts and the upper LH primary timing chain guide.
14. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
15. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
16. Remove the 2 bolts and the LH secondary timing chain tensioner.
17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
18. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
19. Remove the 2 bolts and the RH secondary timing chain tensioner.
20. Remove the 2 bolts and the RH primary timing chain guide.

1. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
4. Position the RH secondary timing assembly onto the camshafts.
5. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
6. Remove the lockpin from the RH secondary timing chain tensioner.
7. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
9. Position the LH secondary timing assembly onto the camshafts.
10. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
11. Remove the lockpin from the LH secondary timing chain tensioner.
12. Install the crankshaft timing chain sprocket.
13. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
14. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
15. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
16. Install the primary timing chain tensioner arm.
17. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
18. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
19. As a post-check, verify correct alignment of all timing marks.
20. Install new VCT housing seals.
21. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
22. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
23. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-293494-S36456647872008080700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove and discard the engine oil filter.
3. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal. Clean and inspect all sealing surfaces.

1. Using a new gasket and O-ring seal, install the oil filter adapter. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in).
2. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Disconnect the engine oil pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 18 Nm (13 lb-ft).
4. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.

1. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) article.
2. Remove the LH heated oxygen sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-293501) article.
3. Remove the 3 bolts and the LH exhaust manifold heat shield.
4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-293455) article.
6. Remove and discard the 6 LH exhaust manifold studs.
7. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
4. Install the LH HO2S. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(ref-293501) article.
5. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) article.

1. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) article.
2. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-293455) article.
5. Remove and discard the 6 RH exhaust manifold studs.
6. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
3. Connect the RH HO2S electrical connector.
4. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) article.

1. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) article.
2. Position a floor jack and the special tool under the oil pan.
3. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
4. Remove the nut, bolt and engine mount brace. To install, tighten to 20 Nm (15 lb-ft).
5. Remove the 4 engine mount nuts. To install, tighten to 63 Nm (46 lb-ft).
6. Remove the 4 engine mount studs. To install, tighten to 18 Nm (13 lb-ft).
7. Remove the 3 bolts and the engine mount. To install, tighten to 90 Nm (66 lb-ft).
8. To install, reverse the removal procedure.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-293494-S36456647872008080700000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 oil pump screen and pickup tube bolts.
14. Remove the 3 oil pump bolts. Rotate the oil pump clockwise and separate the oil pump from the oil pump screen and pickup tube. Remove the oil pump. Discard the oil pump screen and pickup tube O-ring seal.

1. Position the oil pump onto the crankshaft and rotate counterclockwise to position the pump onto the oil pump screen and pickup tube. Install the 3 bolts and tighten to 10 Nm (89 lb-in).
2. Install the 2 oil pump screen and pickup tube bolts. Tighten to 10 Nm (89 lb-in).
3. Install the crankshaft timing chain sprocket.
4. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
5. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Install the primary timing chain tensioner arm.
7. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
9. As a post-check, verify correct alignment of all timing marks.
10. Install new VCT housing seals.
11. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
13. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-293494-S36456647872008080700000) .

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

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
5. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
6. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
8. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
9. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
10. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.
11. Detach the 4 pin-type wiring harness fasteners from the side of the battery tray.
12. Detach the 2 pin-type wiring harness fasteners from the front of the battery tray.
13. Remove the 2 lower battery tray bracket bolts.
14. Remove the nut, bolt and the battery tray and bracket.
15. Disconnect the engine wiring harness electrical connector.
16. Remove the nut and disconnect the power feed wire from the positive battery terminal.
17. Remove the nut and disconnect the ground cable from the negative battery terminal.
18. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
19. Detach the EVAP tube pin-type retainer from the upper intake manifold.
20. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
21. Disconnect the transaxle control cable from the control lever.
22. Disconnect the transaxle control cable from the shift cable bracket and detach the 2 wiring harness pin-type retainers.
23. If equipped, detach the engine block heater harness from the radiator support and the power steering tube.
24. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
25. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
26. Remove the nut and the A/C tube. Discard the O-ring seal.
27. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
28. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
29. Detach the wire harness retainer from the RH valve cover stud bolt.
30. Remove the bolt and the ground cable from the engine.
31. Remove the oil level indicator.
32. Disconnect the hose from the power steering reservoir.
33. Disconnect the transaxle control electrical connector.
34. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
35. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
36. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
37. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
38. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
39. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
40. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
41. Remove and discard the engine oil filter.
42. Remove the power steering pressure (PSP) tube bracket-to-steering gear bolt.
43. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
44. Remove the 2 engine roll restrictor-to-transaxle bolts.
45. Remove and discard the upper stabilizer link nuts.
46. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
47. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the ball joints from the wheel knuckles.
48. Position the special tool under the subframe assembly.
49. Remove the subframe bracket-to-body bolts.
50. Remove the rear subframe bolts and the subframe brackets.
51. Remove the front subframe bolts.
52. Lower the subframe assembly from the vehicle.
53. Using the special tools, separate the LH halfshaft from the transaxle and support halfshaft with a length of mechanic's wire.
54. Remove and discard the RH halfshaft nut.
55. Using the special tool, separate the RH halfshaft from the hub.
56. Remove the 2 RH halfshaft carrier bearing nuts. Remove the RH halfshaft.
57. Remove the 2 RH halfshaft support bracket studs.
58. Remove the 4 bolts and the RH halfshaft support bracket.
59. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
60. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
61. Remove the 2 fasteners and the inspection cover.
62. Remove and discard the 3 torque converter bolts.
63. Remove the 4 oil pan-to-transaxle bolts.
64. Disconnect the RH catalyst monitor electrical connector.
65. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
66. Remove the 5 bolts and the power transfer unit (PTU) support bracket.
67. Remove the 5 bolts and the PTU.
68. Install the special tools.
69. Remove the transaxle mount through bolt and nut.
70. Remove the bolt, 3 nuts and the transaxle mount bracket.
71. Remove the nut, bolt and engine mount brace.
72. Remove the 4 engine mount nuts.
73. Remove the 3 bolts and the engine mount.
74. Lower the engine and transaxle assembly from the vehicle.
75. If equipped, remove the starter motor solenoid cover.
76. Remove the 2 nuts and the starter motor wiring terminals.
77. Disconnect the wiring harness retainer from the starter motor stud bolt.
78. Remove the stud bolt, bolt and the starter.
79. Install the special tool on the LH cylinder head.
80. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
81. Remove the 2 engine-to-transaxle bolts.
82. Remove the 5 transaxle-to-engine bolts. Separate the transaxle from the engine.

All camshafts

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
5. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
6. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
7. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable container.
8. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
9. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
10. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.
11. Detach the 4 pin-type wiring harness fasteners from the side of the battery tray.
12. Detach the 2 pin-type wiring harness fasteners from the front of the battery tray.
13. Remove the 2 lower battery tray bracket bolts.
14. Remove the nut, bolt and the battery tray and bracket.
15. Disconnect the engine wiring harness electrical connector.
16. Remove the nut and disconnect the power feed wire from the positive battery terminal.
17. Remove the nut and disconnect the ground cable from the negative battery terminal.
18. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
19. Detach the EVAP tube pin-type retainer from the upper intake manifold.
20. Disconnect the upper radiator hose, lower radiator hose and one heater hose from the thermostat housing.
21. Disconnect the transaxle control cable from the control lever.
22. Disconnect the transaxle control cable from the shift cable bracket.
23. If equipped, detach the engine block heater wiring harness from the radiator support and the power steering tube.
24. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
25. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
26. Remove the nut and the A/C tube. Discard the O-ring seal.
27. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
28. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
29. Detach the wire harness retainer from the RH valve cover stud bolt.
30. Remove the bolt and the ground cable.
31. Remove the oil level indicator.
32. Disconnect the hose from the power steering reservoir.
33. Disconnect the transaxle control electrical connector.
34. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
35. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
36. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
37. Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
38. Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
39. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
40. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
41. Remove and discard the engine oil filter.
42. Remove the power steering pressure (PSP) tube bracket-to-steering gear bolt.
43. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
44. Remove the 2 engine roll restrictor-to-transaxle bolts.
45. Remove and discard the upper stabilizer link nuts.
46. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
47. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the ball joints from the wheel knuckles.
48. Position the special tool under the subframe assembly.
49. Remove the subframe bracket-to-body bolts.
50. Remove the rear subframe bolts and the subframe brackets.
51. Remove the front subframe bolts.
52. Lower the subframe assembly from the vehicle.
53. Using the special tools, separate the LH halfshaft from the transaxle and support halfshaft with a length of mechanic's wire.
54. Remove and discard the RH halfshaft nut.
55. Using the special tool, separate the RH halfshaft from the hub.
56. Remove the 2 RH halfshaft carrier bearing nuts. Remove the RH halfshaft.
57. Remove the 2 RH halfshaft support bracket studs.
58. Remove the 4 bolts and the RH halfshaft support bracket.
59. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
60. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
61. Install the special tools.
62. Remove the transaxle mount through bolt and nut.
63. Remove the bolt, 3 nuts and the transaxle mount bracket.
64. Remove the nut, bolt and engine mount brace.
65. Remove the 4 engine mount nuts.
66. Remove the 3 bolts and the engine mount.
67. Lower the engine and transaxle assembly from the vehicle.
68. If equipped, disconnect the heated PCV electrical connector.
69. Disconnect the PCV hose from the PCV valve.
70. Disconnect the throttle body (TB) electrical connector.
71. Detach the wiring harness retainers from the upper intake manifold.
72. If equipped, remove the upper intake manifold long support bracket bolt.
73. Remove the upper intake manifold short support bracket bolt.
74. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
75. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
76. Disconnect the RH catalyst monitor electrical connector.
77. Disconnect the fuel efficient power steering system solenoid electrical connector.
78. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
79. Disconnect the 3 RH coil-on-plug electrical connectors.
80. If equipped, disconnect the heated PCV valve electrical connector.
81. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
82. Disconnect the LH VCT solenoid electrical connector.
83. Disconnect the 3 LH coil-on-plug electrical connectors.
84. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
85. Remove the 6 bolts and the 6 coil-on-plug assemblies.
86. Disconnect the PSP switch electrical connector.
87. Remove the PSP tube bracket-to-power steering pump bolt.
88. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
89. Remove the 3 bolts and position aside the power steering pump.
90. Remove the 3 bolts and the accessory drive belt tensioner.
91. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
92. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
93. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the special tools, remove the seal(s).
94. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
95. Using the special tool, remove the crankshaft pulley.
96. Using the special tool, remove and discard the crankshaft front seal.
97. Remove the 2 bolts and the engine mount bracket.
98. Remove the 2 engine mount studs.
99. Remove the 3 bolts and the engine mount bracket.
100. Remove the 22 engine front cover bolts.
101. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
102. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
103. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
104. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
105. Install the special tool onto the flats of the LH camshafts.
106. Install the special tool onto the flats of the RH camshafts.
107. Remove the 3 bolts and the RH VCT housing.
108. Remove the 3 bolts and the LH VCT housing.
109. Remove and discard the VCT housing seals.
110. Remove the 2 bolts and the primary timing chain tensioner.
111. Remove the primary timing chain tensioner arm.
112. Remove the 2 bolts and the lower LH primary timing chain guide.
113. Remove the primary timing chain.
114. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
115. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
116. Remove the special tool from the LH camshafts.
117. Verify the LH camshafts are in the neutral position.
118. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
119. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
120. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
121. Remove the special tool from the RH camshafts.
122. Rotate the RH camshafts counterclockwise to the neutral position.
123. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.

All camshafts

1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
2. Position the camshafts onto the LH cylinder head in the neutral position as shown.
3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the camshafts onto the RH cylinder head in the neutral position as shown.
5. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
6. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «Valve Clearance Check»(ref-293494-S04414098612008080700000) .
7. Rotate the LH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
8. Assemble the LH variable camshaft timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
9. Position the LH secondary timing assembly onto the camshafts.
10. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
11. Remove the lockpin from the LH secondary timing chain tensioner.
12. Rotate the RH camshafts to the TDC position and install the special tool on the flats of the camshafts.
13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
14. Position the RH secondary timing assembly onto the camshafts.
15. Install 2 new bolts and the original washer. 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.
16. Remove the lockpin from the RH secondary timing chain tensioner.
17. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Install the primary timing chain tensioner arm.
21. 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.
22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
23. As a post-check, verify correct alignment of all timing marks.
24. Install new VCT housing seals.
25. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
26. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
27. Install the special tools.
28. 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.
29. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence shown to 3 Nm (27 lb-in).
30. Remove the special tools (alignment pins).
31. Install the engine mount bracket and the 3 bolts.
32. 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).
33. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
34. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
35. Using the special tools, install a new crankshaft front seal.
36. Using the special tools, install the crankshaft pulley.
37. 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.
38. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
39. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
40. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
41. 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.
42. 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).
43. 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.
44. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
45. Install the power steering pressure (PSP) tube bracket and nut to the RH valve cover stud bolt. Tighten to 7 Nm (62 lb-in).
46. Install the PSP tube bracket bolt. Tighten to 10 Nm (89 lb-in).
47. Connect the PSP switch electrical connector.
48. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
49. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
50. Connect the 3 LH coil-on-plug electrical connectors.
51. Connect the LH VCT solenoid electrical connector.
52. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
53. If equipped, connect the heated PCV valve electrical connector.
54. Connect the 3 RH coil-on-plug electrical connectors.
55. Connect the RH VCT solenoid electrical connector.
56. Connect the fuel efficient power steering system solenoid electrical connector.
57. Connect the RH catalyst monitor sensor electrical connector.
58. Using a new gasket, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
59. 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).
60. Install the upper intake manifold short support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
61. If equipped, install the upper intake manifold long support bracket and the bolt. Tighten to 10 Nm (89 lb-in).
62. Attach the wiring harness retainers to the upper intake manifold.
63. Connect the throttle body electrical connector.
64. Connect the PCV hose to the PCV valve.
65. If equipped, connect the heated PCV electrical connector.
66. Raise the engine and transaxle assembly into the vehicle.
67. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
68. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
69. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (15 lb-ft).
70. Install the transaxle support insulator bracket and the 4 nuts. Tighten the nuts to 80 Nm (59 lb-ft).
71. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
72. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-293504) article.
73. 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).
74. Install the 2 halfshaft support bracket studs. Tighten to 10 Nm (89 lb-in).
75. 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).
76. Install the LH halfshaft into the transaxle.
77. Connect the transaxle cooling tubes and install the safety clips.
78. Using the special tool, raise the subframe into the installed position.
79. Install the 2 front subframe bolts. Tighten to 150 Nm (111 lb-ft).
80. Position the subframe brackets and install the 4 bolts finger-tight.
81. Install the 2 rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
82. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
83. Install new lower ball joint-to-wheel knuckle nuts. Tighten to 115 Nm (85 lb-ft).
84. Install new tie-rod end nuts. Tighten to 115 Nm (85 lb-ft).
85. Install new upper stabilizer bar link nuts. Tighten to 55 Nm (41 lb-ft).
86. Install the new halfshaft nut. Tighten to 350 Nm (258 lb-ft).
87. Install the 2 engine roll restrictor-to-transaxle bolts. Tighten to 103 Nm (76 lb-ft).
88. 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).
89. Install the PSP tube bracket-to-steering gear bolt. Tighten to 10 Nm (89 lb-in).
90. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
91. 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).
92. 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.
93. Install the Y-pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
94. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
95. Connect the transaxle control electrical connector.
96. Attach the transaxle control wire harness to the transaxle stud bolt.
97. Connect the hose to the power steering reservoir.
98. Install the oil level indicator.
99. Install the ground cable and bolt. Tighten to 12 Nm (9 lb-ft).
100. Attach the wire harness retainer to the RH valve cover stud bolt.
101. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
102. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
103. Using a new O-ring seal, install the A/C tube and the nut. Tighten to 15 Nm (11 lb-ft).
104. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 15 Nm (11 lb-ft).
105. 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).
106. If equipped, attach the block heater wiring harness retainer to the radiator and power steering tube.
107. Connect the transaxle control cable to the shift cable bracket.
108. Connect the transaxle control cable to the control lever.
109. If equipped, connect the heater hose to the auxiliary coolant pump.
110. Connect the upper radiator hose, lower radiator hose and heater hose to the thermostat housing.
111. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.
112. Attach the EVAP tube pin-type retainer to the upper intake manifold.
113. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
114. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
115. Connect the engine wiring harness electrical connector.
116. Install the battery tray and bracket and the nut and bolt. Tighten to 9 Nm (80 lb-in).
117. Install the 2 lower battery tray bracket bolts. Tighten to 9 Nm (80 lb-in).
118. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
119. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
120. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.
121. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
122. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
123. Connect the power steering cooler tube.
124. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-293461) article.
125. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-293452) article.
126. Fill the engine with clean engine oil.
127. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-293488) article.
128. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-293459) article.
129. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-293458) article.