Mustang 2010 PDF

2010 Ford Mustang Shelby GT500
2010 ENGINE Engine - 4.0L SOHC - Mustang
2010 ENGINE
Engine - 4.0L SOHC - Mustang
SPECIFICATIONS
MATERIAL SPECIFICATIONS
Item Specification Fill Capacity
Motorcraft® Metal Surface Prep
- -
ZC-31-A
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil
WSS-M2C929- 4.73L (5 qt)
XO-5W30-QSP (US); Motorcraft® SAE 5W-30 Super Premium Motor
A with filter
Oil CXO-5W30-LSP12 (Canada); or equivalent
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-
-
XG-3-A A
Silicone Gasket and Sealant WSE-M4G323-
-
TA-30 A4
Silicone Gasket Remover
- -
ZC-30
Thread Sealant with PTFE WSK-M2G350-
-
TA-24 A2
ITEM SPECIFICATION
ITEM SPECIFICATION
Item Specification
Engine
Displacement 4.0L (244 CID)
Number of cylinders 6
Bore 100.4 mm (3.953 in)
Stroke 84.4 mm (3.32 in)
Firing order 1-4-2-5-3-6
Oil pressure minimum at 2,000 RPM (engine at normal
103 kPa (15 psi)
operating temperature)
Engine weight (without accessory drive components
189 kg (416.7 lb)
and flexplate or flywheel)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness 0.08 mm (0.003 in) total
Combustion chamber volume 65.197 ± 2.068-2.018 cc
Valve arrangement (front to rear) - LH I-E-I-E-I-E
Valve arrangement (front to rear) - RH E-I-E-I-E-I
Valve guide bore diameter 7.00-7.018 mm (0.276 in)
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Valve stem diameter - intake 6.965-6.98 mm (0.274-0.275 in)

Valve stem diameter - exhaust 6.95-6.965 mm (0.27-0.274 in)
Valve stem-to-guide clearance - intake 0.020-0.053 mm (0.001-0.002 in)
Valve stem-to-guide clearance - exhaust 0.035-0.068 mm (0.001-0.003 in)
Valve head diameter - intake 45.9-46.1 mm (1.807-1.815 in)
Valve head diameter - exhaust 38.9-39.1 mm (1.531-1.539 in)
Valve face runout 0.03 mm (0.001 in)
Valve face angle 45 degrees
Valve seat width - intake 1.273-2.121 mm (0.05-0.083 in)
Valve seat width - exhaust 1.556-2.404 mm (0.061-0.095 in)
Valve seat runout 0.059 mm (0.002 in)
Valve seat angle 45 degrees
Valve spring free length 43.1 mm (1.7 in)
Valve spring squareness ± 1.5 deg
Valve spring compression pressure at specified height 275-305 Nm at 35.9-36.7 mm (202.84-224.968
(lbs) lb-ft at 1.413-1.445 in)
Valve spring installed height 39.86-40.86 mm (1.569-1.609 in)
Valve spring installed pressure 320 N (72 lb)
Roller follower ratio 1.98:1
Camshaft
Theoretical valve lift @ 0 lash 11.93 mm (0.472 in)
Lobe lift 6.584 mm (0.259 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 27.935-27.96 mm (1.099-1.101 in)
Camshaft journal bore inside diameter 28.0-28.03 mm (1.102-1.104 in)
Camshaft journal-to-bearing clearance 0.04-0.095 mm (0.002-0.004 in)
Runout 0.05 mm (0.002 in)
End play 0.075-0.185 mm (0.003-0.007 in)
Cylinder Block
Cylinder bore diameter 100.4 mm (3.953 in)
Cylinder bore maximum taper 0.025 mm (0.001 in)
Cylinder bore maximum out-of-round 0.025 mm (0.001 in)
Main bearing bore inside diameter 60.620-60.634 mm (2.387-2.387 in)
Head gasket surface flatness 0.1 mm (0.004 in) overall
Crankshaft
Main bearing journal diameter 56.980-57.0 mm (2.243-2.244 in)
Main bearing journal maximum taper 0.008 mm (0.0003 in)
Main bearing journal maximum out-of-round 0.008 mm (0.0003 in)
Main bearing journal-to-cylinder block clearance 0.008-0.062 mm (0.0003-0.0024 in)
Connecting rod journal diameter 53.98-54.0 mm (2.125-2.126 in)
Connecting rod journal maximum taper 0.008 mm (0.0003 in)
Connecting rod journal maximum out of round
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0.008 mm (0.0003 in)

Crankshaft maximum end play 0.05-0.32 mm (0.002-0.0126 in)
Main Bearings
Clearance to crankshaft 0.021-0.039 mm (0.0008-0.0015 in)
Clearance to crankshaft allowable 0.013-0.048 mm (0.0005-0.002 in)
Bearing wall thickness 1.8-1.806 mm (0.0709-0.0711 in)
Piston and Connecting Rod
Piston diameter - coded standard 100.36-100.400 mm (3.951-3.9528 in)
Piston diameter - coded 0.5 100.880-100.900 mm (3.971-3.972 in)
Piston diameter - coded 1.0 101.390-101.400 mm (3.991-3.992 in)
Piston-to-cylinder bore clearance 0.030-0.050 mm (0.0012-0.002 in)
Piston ring end gap - top 0.250-0.400 mm (0.009-0.015 in)
Piston ring end gap - bottom 0.40-0.65 mm (0.016-0.025 in)
Piston ring groove width - top 1.23-1.25 mm (0.0484-0.0492 in)
Piston ring groove width - bottom 1.52-1.54 mm (0.0598-0.0606 in)
Piston ring groove width - oil ring 3.01-3.03 mm (0.1185-0.1193 in)
Piston ring width - top 1.170-1.190 mm (0.0460-0.0469 in)
Piston ring width - bottom 1.472-1.490 mm (0.0580-0.0587 in)
Piston ring-to-groove clearance - top 0.040-0.080 mm (0.0016-0.0031 in)
Piston ring-to-groove clearance - bottom 0.030-0.068 mm (0.0012-0.0027 in)
Piston pin bore diameter 24.009-24.013 mm (0.9452-0.9453 in)
Piston pin diameter (red) 23.997-24.000 mm (0.9447-0.9448 in)
Piston pin length 71.8-72.3 mm (2.826-2.846 in)
Piston pin-to-piston fit 0.009-0.016 mm (0.0003-0.0006 in)
Connecting rod pin bore diameter 23.958-23.976 mm (0.943-0.944 in)
Connecting rod length (center-to-center) 145.965-146.035 mm (5.747-5.749 in)
Connecting rod maximum allowed bend 0.0125 mm (0.0004 in) per 25.4 mm (1.000 in)
Connecting rod maximum allowed twist 0.038 mm (0.0015 in) per 25.4 mm (1.000 in)
Connecting rod bearing bore diameter 56.82 mm-56.84 mm (2.237 in-2.238 in)
Connecting rod bearing-to-crankshaft clearance 0.022-0.064 mm (0.0008-0.0025 in)
Connecting rod side clearance 0.092-0.318 mm (0.0036-0.0125 in)
TORQUE SPECIFICATIONS CHART
TORQUE SPECIFICATIONS CHART

Description Nm lb-ft lb-in
Accessory drive belt tensioner bolt 47 35 -
Accessory drive belt idler pulley bolt 47 35 -
Balance shaft bolts 27 20 -
Balance shaft chain guide bolts 10 - 89
Balance shaft chain tensioner bolts 29 21 -
Bell housing-to-cylinder block cradle bolts 47 35 -

Camshaft bearing cap bolts(1) - - -
Camshaft sprocket bolt 85 63 -
Camshaft sprocket holding tool bolts 10 - 89
Camshaft tensioners 44 32 -
Catalytic converter-to-exhaust manifold nuts 45 33 -
Connecting rod bolts and nuts(1) - - -
Coolant hose bracket bolt 45 33 -
Coolant pump bolts 10 - 89
Coolant tube bracket bolt (M8) 23 17 -
Coolant tube bracket bolt (M12) 34 25 -
Crankshaft Position (CKP) sensor bolts 10 - 89
Crankshaft pulley bolt(1) - - -
Crankshaft main bearing cap bolts(1) - - -
Cylinder block cradle bolts 14 - 124
Cylinder block cradle nuts 10 - 89
Cylinder block cradle bolts (inside)(1) - - -
Cylinder block cradle Torx bolts 10 - 89
Cylinder block cradle rear Torx bolts 10 - 89
Cylinder block cradle inserts 3 - 27
Cylinder head bolts (M8)(1) - - -
Cylinder head bolts (M12)(1) - - -
Engine wiring harness-to-cylinder head bolts 40 30 -
Engine front cover bolts and stud bolts 19 - 168
Engine mount bracket bolts 80 59 -
Engine mount nut 63 46 -
Engine mount bolts 70 52 -
Exhaust manifold-to-EGR system module tube fittings 40 30 -
Exhaust manifold nuts 23 17 -
Exhaust manifold studs 12 - 106
Flexplate/flywheel bolts(1) - - -
Front End Accessory Drive (FEAD) bracket bolts 48 35 -
Fuel rail bolts 23 17 -
Fuel rail supply tube bracket-to-LH valve cover bolt 6 - 53
Fuel rail supply tube bracket-to-LH cylinder head bolt 10 - 89
Generator bracket bolts and nut 47 35 -
Generator B+ terminal nut 8 - 71
Ground cable-to-RH strut tower bolt 10 - 89
Ground strap-to-cylinder block stud bolt 10 - 89
Ground strap-to-LH cylinder head bolt 40 30 -
Hood hinge bolts 12 - 106

Hydraulic chain tensioner, LH 44 32 -
Hydraulic chain tensioner, RH 44 32 -
Ignition coil bracket upper bolts 9 - 80
Ignition coil bracket lower bolts (M12) 34 25 -
Ignition coil bracket lower bolt (M8) 24 18 -
Intake manifold bolts(1) - - -
Jackshaft chain guide bolts 19 - 168
Jackshaft chain tensioner bolts 9 - 80
Jackshaft rear sprocket bolt(1) - - -
Jackshaft front sprocket bolt(1) - - -
Jackshaft thrust plate bolts 11 - 97
Knock Sensor (KS) bolt 20 - 177
LH cassette-to-cylinder head bolt 12 - 106
LH cassette-to-cylinder block bolt 19 - 168
Oil filter(1) - - -
Oil filter adapter bolt 57 42 -
Oil level indicator tube bracket bolt 11 - 97
Oil pan bolts 11 - 97
Oil pan drain plug 26 19 -
Oil pump intermediate shaft bolts 19 - 168
Oil pump bolts 19 - 168
Oil pump drive bolt 19 - 168
Oil pump screen and pickup tube bolt 11 - 97
Power Distribution Box (PDB) B+ terminal bolt 12 - 106
PDB electrical connector bolt 6 - 53
Power Steering Pressure (PSP) tube-to-crossmember bolt 11 - 97
Power steering supply hose bracket-to- FEAD bracket bolt 11 - 97
Power steering pump bolts 25 18 -
Power steering pump pulley bolts 25 18 -
Pressure tube bracket nut 7 - 62
RH cassette-to-cylinder block bolt 12 - 106
RH cassette-to-cylinder head bolt 10 - 89
Spark plug 17 - 150
Starter motor wiring harness retainer bracket bolt 40 30 -
Steering column intermediate shaft-to-steering gear bolt 25 18 -
Steering gear-to-crossmember bolts 115 85 -
Suction hose bracket bolt 8 - 71
Thermostat housing bolts 11 - 97
Valve cover bolts and stud bolts(1) - - -
(1) Refer to the procedure.
DESCRIPTION AND OPERATION

ENGINE
The 4.0L SOHC engine consists of the following:
l Single overhead camshafts

l Sequential Multi-Port Fuel Injection (SFI)
l Distributorless ignition system
l Aluminum cylinder heads
l Cast iron, 60-degree V cylinder block
l Balance shaft (manual transmission only)
l Jackshaft
l Unique engine timing configuration
Engine Identification
Always refer to these labels when installation of new parts is necessary or when checking engine calibrations.
The engine parts often differ within a CID family. Verification of the identification codes will make sure that
the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional
equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their
applications.
Engine Code Information Label
The engine code information label is located on the side of the LH valve cover, it contains the following:
Fig. 1: Identifying Engine Code Information Label

Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION
Item Description
1 Engine part number
2 Bar code
3 Running number
4 Engine build date (DDMMYY)
5 Plant shift assembly line
6 Cologne engine plant
7 Engine displacement
8 Engine build date (DDMMYY)
9 Bar code
Engine Cylinder Identification
Fig. 2: Identifying Engine Cylinder Identification Label

Exhaust Emission Control System
Operation and required maintenance of the exhaust emission control devices used on this engine is covered in
the INTRODUCTION - GASOLINE MODELS .
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The fuel charging and controls
system consists of the:
l electronic Throttle Body (TB).

l fuel injectors.
l fuel rail.
l fuel rail pressure and temperature sensor.
The fuel charging and controls system is:
l Pulse Width Modulated (PWM).

l Mass Air Flow (MAF)-controlled.
PCV System
The PCV valve:
l controls the amount of ventilating air and blow-by gases going to the intake manifold.
EGR System
The EGR system module transducer:
l monitors the EGR system module flow rate through the EGR-to-exhaust manifold tube.
l sends an EGR system module flow rate signal to the PCM.
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied to the crankshaft, connecting rod
bearings, camshaft roller followers, hydraulic lash adjusters and camshafts.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through its
entire operating range.
Generically this design is known as a gerotor pump, which operates as follows:
l Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure
both at hot idle and maximum speed.
l The oil pump is mounted on the bottom side of the crankshaft.
l The oil pump is driven by a oil pump intermediate shaft.
l The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
l The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high-speed conditions.
Cooling System
The engine cooling system includes the following:
l Radiator
l Degas bottle (aids in maintaining the correct volume of engine coolant)
l Coolant thermostat
l Coolant hoses
l Single electric fan
DIAGNOSIS AND TESTING

ENGINE
For basic mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .
For driveability concerns, refer to the INTRODUCTION - GASOLINE MODELS .
GENERAL PROCEDURES
CAMSHAFT TIMING
Special Tool(s)
SPECIAL TOOLS DESCRIPTION CHART
Adapter for 303-564

303-578 (T97T-6256-C)
Adapter for 303-577

303-576 (T97T-6256-D)
Holding Tool, Camshaft

303-577 (T97T-6303-C)
Holding Tool, Camshaft Sprocket

303-564 (T97T-6256-B)
Socket, Camshaft Sprocket Nut

303-565 (T97T-6256-G)
Tensioner, Timing Chain

303-571 (T97T-6K254-A)
Timing Tool, Crankshaft TDC

303-573 (T97T-6303-A)
Torque Wrench Extension

303-575 (T97T-6256-F)
1. Remove the camshaft roller followers. For additional information, refer to CAMSHAFT ROLLER
FOLLOWER.
2. Remove the generator. For additional information, refer to CHARGING SYSTEM .
3. Remove the Engine Coolant Temperature (ECT) sensor. For additional information, refer to
ELECTRONIC ENGINE CONTROLS .
NOTE: The LH and RH camshafts must be retimed when either camshaft is

disturbed.
4. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
NOTE: Do not rotate the engine counterclockwise. Rotating the engine

counterclockwise will result in damage to the damper crank sensor speed
wheel and incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and
should contact the engine block, this positions the engine at TDC .
Fig. 3: Identifying Crankshaft TDC Timing Tool

5. Install the Crankshaft TDC Timing Tool.

6. Install the Camshaft Sprocket Holding Tool and Adapter to the RH cylinder head and tighten the 2 top
clamp bolts.
l Tighten to 10 Nm (89 lb-in).
Fig. 4: Locating Camshaft Sprocket Holding Tool, Adapter With Clamp Bolts
NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.
Fig. 5: Removing/Installing Camshaft Sprocket Bolt Using Torque Wrench Extension

7. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, loosen the RH
camshaft sprocket bolt.
8. Loosen the top 2 Camshaft Sprocket Holding Tool clamp bolts.
Fig. 6: Locating Camshaft Sprocket Holding Tool Clamp Bolts

NOTE: The camshaft timing slots are off-center.
Fig. 7: Identifying Camshaft Holding Tool And Adapter On Front Of Cylinder Head (RH)
9. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapter and
install the Camshaft Holding Tool and Adapter on the front of the RH cylinder head.
10. Remove the RH camshaft tensioner.
l Remove and discard the washer.
Fig. 8: Locating RH Camshaft Tensioner

11. Install the Timing Chain Tensioner.
Fig. 9: Identifying Timing Chain Tensioner

12. Tighten the bolts.

1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the
camshaft bolt.
Fig. 10: Tightening RH Camshaft Sprocket Bolt

13. Remove the Timing Chain Tensioner.

NOTE: Install a new washer on the tensioner.
14. Install the RH camshaft tensioner.

l Tighten to 44 Nm (32 lb-ft).

15. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head and tighten
the top 2 clamp bolts.
Fig. 13: Identifying Camshaft Sprocket Holding Tool And Adapter

16. Loosen the LH camshaft sprocket bolt.
Fig. 14: Locating LH Camshaft Sprocket Bolt

17. Loosen the top 2 clamp bolts on the Camshaft Sprocket Holding Tool to allow the camshaft sprocket to
rotate freely.
Fig. 15: Locating Clamp Bolts On Camshaft Sprocket Holding Tool

Fig. 16: Identifying Camshaft Holding Tool And Adapter On Rear Of Cylinder Head (LH)
18. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapter, and
install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.
19. Remove the LH camshaft tensioner.
Fig. 17: Locating LH Camshaft Tensioner


2. Tighten the LH camshaft bolt to 85 Nm (63 lb-ft).
Fig. 19: Tightening LH Camshaft Bolt

22. Remove the Timing Chain Tensioner.

NOTE: Install a new washer on the tensioner.
23. Install the LH camshaft tensioner.


24. Install the ECT sensor. For additional information, refer to ELECTRONIC ENGINE CONTROLS .
25. Install the generator. For additional information, refer to CHARGING SYSTEM .
26. Install the camshaft roller followers. For additional information, refer to CAMSHAFT ROLLER
FOLLOWER.
IN-VEHICLE REPAIR
INTAKE MANIFOLD
Intake Manifold (View 1 of 2)
Fig. 22: Exploded View Of Intake Manifold With Torque Specifications (1 Of 2)

ITEM DESCRIPTION
Item Part Number Description
1 14A464 Radio capacitor electrical connector
2 W500214 Ignition coil bracket upper bolts
3 12280 RH spark plug wire-to-ignition coil connector (3 required)
4 12A310 Ignition coil and bracket assembly
5 W500041 Ignition coil bracket lower bolt (M12)
7 2C053 Brake booster vacuum hose
8 - Vacuum harness fitting (part of 9E498)
9 9G271 Vapor tube
10 - EGR system module tube fitting (part of 9E469)
11 14A464 EGR system module electrical connector (part of 12B637)
12 14A464 Throttle Position (TP) sensor electrical connector (part of
12B637)
13 14A464 Throttle Body (TB) electrical connector (part of 12B637)
14 6K817 PCV tube
15 14A624 Knock Sensor (KS) electrical connector (part of 12B637)
16 12280 RH spark plug wire retainer
Intake Manifold (View 2 of 2)
Fig. 23: Exploded View Of Intake Manifold (2 Of 2)

ITEM DESCRIPTION
1 9Y450 Intake manifold bolt (8 required)
2 9424 Intake manifold
3 9439 Intake manifold gasket (6
required)
Removal
NOTE: During engine repair procedures, cleanliness is extremely important. Any

foreign material, including any material created while cleaning gasket surfaces
that enters the oil passages, coolant passages or the oil pan, can cause engine
failure.
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR
DISTRIBUTION & FILTERING .
2. Disconnect the radio capacitor electrical connector.
3. Disconnect the RH spark plug wires from the ignition coil.
4. Detach the RH spark plug wire retainer from the intake manifold.
5. Remove the 2 ignition coil bracket upper bolts.
6. Remove the 2 ignition coil lower bolts.
l Position the ignition coil and bracket assembly aside.
7. Disconnect the EGR system module electrical connector.

8. Disconnect the EGR system module tube from the EGR system module.
9. Disconnect the brake booster vacuum hose from the intake manifold.
10. Disconnect the vacuum tube from the fuel rail pressure and temperature sensor.
11. Disconnect the vapor tube from the intake manifold.
12. Remove the PCV tube.
13. Detach the Knock Sensor (KS) electrical connector retainer from the intake manifold.
14. Disconnect the Throttle Position (TP) sensor and Throttle Body (TB) electrical connectors.
15. Remove the 8 bolts and the intake manifold.
Installation
NOTE: If the engine is repaired or replaced because of upper engine failure,

typically including valve or piston damage, check the intake manifold for
metal debris. If metal debris is found, install a new intake manifold. Failure
to follow these instructions can result in engine damage.
NOTE: Clean and inspect all sealing surfaces. Inspect and install new gaskets as
necessary.
1. Position the intake manifold and install the 8 bolts.

l Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig. 24: Intake Manifold Bolts Tightening Sequence

2. Connect the TP sensor and TB electrical connectors.
3. Attach the KS electrical connector retainer to the intake manifold.

4. Install the PCV tube.
5. Connect the vapor tube to the intake manifold.
6. Connect the vacuum tube to the fuel rail pressure and temperature sensor.
7. Connect the brake booster vacuum hose to the intake manifold.
8. Connect the EGR system module tube to the EGR system module.
9. Connect the EGR system module electrical connector.

10. Position the ignition coil and bracket assembly. Install the 2 lower bolts.
l Tighten the M8 bolt to 24 Nm (18 lb-ft).
11. Install the 2 ignition coil bracket upper bolts.

12. Attach the RH spark plug wire retainer to the intake manifold.
13. Connect the RH spark plug wires to the ignition coil.
14. Connect the radio capacitor electrical connector.
15. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION &
FILTERING .
VALVE COVER - LH
Material
Item Specification
-
ZC-31-A
Fig. 25: Exploded View Of Valve Cover - LH With Torque Specifications

ITEM DESCRIPTION
1 W500213 Fuel rail supply tube bracket-to-cylinder head bolt
2 14A464 Radio capacitor electrical connector
3 12280 Spark plug wire-to-ignition coil connector (6 required)
4 W500214 Ignition coil bracket upper bolts
7 12A310 Ignition coil and bracket assembly
8 14A464 Fuel rail pressure and temperature sensor electrical connector (part of
12B637)
9 13A506 Wiring harness retainer (part of 12B637)

10 14A464 Fuel injector electrical connector (3 required) (part of 12B637)
11 W500213 Fuel rail supply tube bracket-to-valve cover bolt
12 - Fuel rail supply tube bracket (part of 9E964)
13 14A464 Camshaft Position (CMP) sensor electrical connector (part of 12B637)
14 6758 Crankcase ventilation tube
15 6C519 LH valve cover stud bolt (3 required)
16 6C519 LH valve cover bolt (3 required)
17 6A505 LH valve cover assembly
18 6584 LH valve cover gasket
Removal

failure.
1. Disconnect the radio capacitor electrical connector.

2. Disconnect the 6 spark plug wires from the ignition coil.
3. Remove the 2 upper ignition coil bracket bolts.
4. Remove the 2 lower ignition coil bracket bolts and remove the ignition coil and bracket assembly.
5. Remove the fuel rail supply tube bracket-to-cylinder head bolt.
6. Remove the fuel rail supply tube bracket-to-valve cover bolt.
l Position the fuel rail supply tube aside.
7. Disconnect the crankcase ventilation tube from the valve cover and position the tube aside.
8. Disconnect the Camshaft Position (CMP) sensor electrical connector.
9. Disconnect the fuel rail pressure and temperature sensor electrical connector.
10. Disconnect the 3 LH fuel injector electrical connectors.
l Detach the wiring retainer from the valve cover stud bolt and position the wiring harness aside.
11. Detach the spark plug wire retainer from the valve cover stud bolt.
12. Remove the 3 bolts, the 3 stud bolts and the LH valve cover.
Installation
NOTE: Clean the valve cover and cylinder head sealing surfaces with metal
surface prep. Inspect and install a new gasket as necessary.
1. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
Fig. 26: Identifying Valve Cover Bolts Tightening Sequence (LH)

2. Attach the spark plug wire retainer to the valve cover stud bolt.
3. Position the wiring harness, attach the wiring retainer to the valve cover stud bolt and then connect the 3
LH fuel injector electrical connectors.
4. Connect the fuel rail pressure and temperature sensor electrical connector.
5. Connect the CMP sensor electrical connector.
6. Connect the crankcase ventilation tube to the valve cover.
7. Position the fuel rail supply tube and install the fuel rail supply tube bracket-to-valve cover bolt.
8. Install the fuel rail supply tube bracket-to-cylinder head bolt.

9. Install the ignition coil and bracket assembly and the lower bolts.
l Tighten the M8 bolts to 24 Nm (18 lb-ft).
10. Install the upper ignition coil bracket bolts.

11. Connect the 6 spark plug wire to the ignition coil.

12. Connect the radio capacitor electrical connector.
VALVE COVER - RH
Material
Item Specification
-
ZC-31-A
Valve Cover - RH (View 1 of 2)
Fig. 27: Exploded View Of Valve Cover - RH (1 Of 2)

ITEM DESCRIPTION
1 6K817 PCV tube
2 - PCV valve electrical connector (part of 12A580)
3 8W287 Heater hose retainer bracket
Valve Cover - RH (View 2 of 2)
Fig. 28: Exploded View Of Valve Cover - RH With Torque Specifications (2 Of 2)

ITEM DESCRIPTION
4 W506031 Wiring harness bracket bolt
5 14536 Wiring harness bracket (part of
12B637)
6 6C519 RH valve cover stud bolt (4 required)
7 13A506 Wiring retainer (part of 12B637)
8 6C519 RH valve cover bolt (2 required)
9 6582 RH valve cover assembly
10 6584 RH valve cover gasket
Removal

failure.
1. Remove the PCV tube.

2. Disconnect the PCV valve electrical connector.
3. Detach the heater hose retainer from the valve cover.
4. Remove the wiring harness bracket bolt from the back of the RH cylinder head and detach the bracket
from the valve cover stud bolt.
5. Detach the engine wiring and spark plug wiring retainers from the 2 valve cover stud bolts.
6. Remove the 2 bolts, the 4 stud bolts and the RH valve cover.
Installation
NOTE: Clean the valve cover and cylinder head sealing surfaces with metal
surface prep. Inspect and install a new gasket as necessary.
1. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
Fig. 29: Identifying Valve Cover Bolts Tightening Sequence (RH)

2. Attach the engine wiring and spark plug wiring retainers to the 2 valve cover stud bolts.
3. Position the wiring harness bracket on the valve cover stud bolt and install the wiring harness bracket bolt
to the back of the RH cylinder head.
4. Attach the heater hose retainer to the valve cover.

5. Connect the PCV valve electrical connector.
LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT

FRONT SEAL
Fig. 30: Exploded View Of Crankshaft Pulley And Crankshaft Front Seal
ITEM DESCRIPTION
1 E800511 Crankshaft pulley bolt
2 - Washer
3 6B321 Crankshaft pulley
4 6700 Crankshaft front oil seal
1. For additional information, refer to the procedures.
CRANKSHAFT PULLEY
Special Tool(s)
Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)
Remover, Crankshaft Vibration Damper

303-101 (T74P-3616-A)

303-773
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
General Equipment
GENERAL EQUIPMENT CHART

8-mm x 1.25 x 100-mm bolts (2 required)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR
3. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
NOTE: This bolt is torque-to-yield and cannot be reused.
Fig. 31: Holding Crankshaft Pulley Using Strap Wrench

4. Using the Strap Wrench, hold the crankshaft pulley, remove the bolt and washer.
NOTE: If the pulley bolt is not installed, the Crankshaft Vibration Damper
Remover will bottom out before the pulley is off.
5. Install the crankshaft pulley bolt 2 to 3 turns. Using the Crankshaft Vibration Damper Removers and the
two 8-mm bolts, remove the crankshaft pulley.
l Discard the crankshaft pulley bolt.
Fig. 32: Removing Crankshaft Pulley

Installation
1. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
Fig. 33: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer
2. Using the Strap Wrench, hold the crankshaft pulley, install a new crankshaft pulley bolt. Tighten the bolt
in 2 stages.
l Stage 1: Tighten to 55 Nm (41 lb-ft).
l Stage 2: Tighten an additional 85 degrees.

3. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
4. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION &
FILTERING .
CRANKSHAFT FRONT SEAL
Special Tool(s)
Aligner, Front Cover

303-093 (T74P-6019-A)

303-102 (T74P-6316-B)
Remover, Crankshaft Front Oil Seal

303-107 (T74P-6700-A)
Material
Item Specification
WSS-M2C929-
XO-5W30-QSP (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil CXO-5W30-
A
LSP12 (Canada); or equivalent
Removal
1. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY.
2. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
Fig. 35: Locating Crankshaft Front Oil Seal And Crankshaft Front Oil Seal Remover
Installation
NOTE: Lubricate the new front seal with clean engine oil.
Fig. 36: Locating Crankshaft Front Oil Seal With Front Cover Aligner And Crankshaft Vibration
Damper Installer
1. Using the Front Cover Aligner and Crankshaft Vibration Damper Installer, install a new crankshaft front
seal.
2. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY.
LOWER END COMPONENTS - EXPLODED VIEW, FLEXPLATE, FLYWHEEL AND

CRANKSHAFT REAR SEAL
NOTE: Flexplate shown in illustration, flywheel similar.
Fig. 37: Exploded View Of Flexplate, Flywheel And Crankshaft Rear Seal
ITEM DESCRIPTION
1 6379 Flexplate/flywheel bolt (8 required)
2 6375 Flexplate/flywheel
3 6A373 Spacer plate
4 6434 Flexplate-to-crankshaft spacer (automatic transmission
only)
5 6701 Crankshaft rear oil seal
FLYWHEEL
Removal
1. Remove the clutch. For additional information, refer to CLUTCH .

2. Remove the 8 bolts and the flywheel.
l Discard the bolts.
Installation
NOTE: New flywheel bolts must be installed. They are a torque-to-yield design
and cannot be reused.
1. Position the flywheel. Install the 8 new bolts and tighten in the sequence shown in illustration in 3 stages.
l Stage 1: Tighten to 13 Nm (115 lb-in).
Fig. 38: Identifying Flywheel Bolts Tightening Sequence
2. Install the clutch. For additional information, refer to CLUTCH .
FLEXPLATE
Removal
1. Remove the transmission. For additional information, refer to AUTOMATIC

TRANSAXLE/TRANSMISSION - 5R55S .
2. Remove the 8 bolts, the flexplate and the flexplate-to-crankshaft spacer.
Installation
NOTE: New flexplate bolts must be installed. They are a torque-to-yield design
and cannot be reused.
1. Position the spacer and the flexplate. Install the 8 new bolts and tighten in the sequence shown in
illustration in 3 stages.
Fig. 39: Identifying Flexplate Bolts Tightening Sequence

2. Install the transmission. For additional information, refer to AUTOMATIC

CRANKSHAFT REAR SEAL
Special Tool(s)
Adapter for 303-579 (part of 303-S524)

303-527 (T95P-6701-A3)
Installer, Crankshaft Rear Oil Seal

303-579 (T97T-6701-A)
Remover, Oil Seal

303-409 (T92C-6700-CH)
Screws, Crankshaft Rear Oil Seal (part of 303-

S524)
303-528 (T95T-6701-A4)
Material
Item Specification
-
ZC-31-A
WSS-M2C929-
A
Removal
1. Remove the flexplate or flywheel. For additional information, refer to FLEXPLATE or FLYWHEEL.
2. Remove the spacer plate.
NOTE: The original crankshaft rear seal does not have a speedy sleeve. Only a
new replacement crankshaft rear seal comes with a speedy sleeve.
NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve
must be removed before attempting to remove the seal.
Fig. 40: Locating Speedy Sleeve

3. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
NOTE: Avoid scratching or damaging the crankshaft rear seal running surface
during removal of the crankshaft rear seal.
Fig. 41: Removing Crankshaft Rear Seal Using Oil Seal Remover
4. Using the Oil Seal Remover, remove the crankshaft rear seal.
Installation
NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. Do
not remove the speedy sleeve, it must be installed with the crankshaft rear
seal.
NOTE: Be sure the crankshaft rear sealing surface is clean and free from any rust
or corrosion. To clean the crankshaft rear seal surface area, use extra-fine
emery cloth or extra-fine 0000 steel wool with metal surface prep.
1. Lubricate the crankshaft rear oil seal with clean engine oil.
2. Install the Crankshaft Rear Oil Seal Screws and Adapter.
Fig. 42: Identifying Crankshaft Rear Oil Seal Screws And Adapter
3. Position the crankshaft rear seal with speedy sleeve around the Crankshaft Rear Oil Seal Screws and
Adapter.
Fig. 43: Identifying Crankshaft Rear Oil Seal Screws And Adapter
4. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear seal with speedy sleeve.
Fig. 44: Installing Crankshaft Rear Oil Seal Using Crankshaft Rear Oil Seal Installer
5. Install the flexplate-to-crankshaft spacer.

6. Install the spacer plate.
7. Install the flexplate or flywheel. For additional information, refer to FLEXPLATE or FLYWHEEL.
ENGINE FRONT COVER
Special Tool(s)

303-093 (T74P-6019-A)
Material
Item Specification
ZC-31-A -
XO-5W30-QSP (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil CXO- WSS-M2C929-A
5W30-LSP12 (Canada); or equivalent
TA-30 A4
-
ZC-30
TA-24 A2
Fig. 45: Exploded View Of Engine Front Cover With Torque Specifications
ITEM DESCRIPTION
1 14A464 Crankshaft Position (CKP) sensor electrical connector (part of
12B637)
2 - Wiring retainer (part of 12B637)
3 W702501 Engine front cover stud bolt (4 required)
4 8287 Clamp
5 18C266 Coolant hose
6 W702501 Engine front cover stud bolt
7 W500024 Engine front cover bolt (5 required)
8 15161 Clamp
9 8286 Lower radiator hose
10 E802185 Block cradle-to-engine front cover bolt (5 required)
11 - Accessory drive belt idler pulley bolt (part of 6C348)
12 6C348 Accessory drive belt idler pulley
13 15161 Clamp
14 8620 Upper radiator hose
15 6019 Engine front cover
16 - Engine front cover gasket
Removal

failure.
1. Drain the cooling system. For additional information, refer to ENGINE COOLING .
2. Remove the crankshaft front oil seal. For additional information, refer to CRANKSHAFT FRONT
SEAL.
3. Disconnect the upper radiator hose.
4. Disconnect the heater hose from the coolant pump.
5. Disconnect the lower radiator hose from the coolant pump.
6. Remove the bolt and the accessory drive belt idler pulley.
7. Disconnect the Crankshaft Position (CKP) sensor and detach the 2 wiring retainers.
8. Remove the 5 engine block cradle-to-engine front cover bolts.
9. Remove the 5 bolts and the 5 stud bolts from the engine front cover.
10. Disconnect the coolant bypass hose from the coolant pump and remove the engine front cover.
NOTE: Make sure that any coolant that drains into the front corners of the engine
block cradle is removed.
11. Remove the oil pan drain plug and drain the engine oil.
l Install the drain plug and tighten to 26 Nm (19 lb-ft).
Installation
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools cause scratches
and gouges which make leak paths.
1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a
plastic or wooden scraping tool. Follow the directions on the packaging.

2. Position a new front cover gasket.
NOTE: If not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area, use silicone gasket
remover and metal surface prep. Follow the directions on the packaging.
Failure to follow this procedure can cause future oil leakage.
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
Fig. 46: Silicone Gasket And Sealant Applying Location On Oil Pan And Engine Block Mating
Surfaces
4. Apply silicone gasket and sealant to the front cover in 2 places.
Fig. 47: Silicone Gasket And Sealant Applying Locations On Front Cover
NOTE: Apply thread sealant to the stud bolts and make sure that the stud bolts
are installed in their original positions.
5. Position the front cover and connect the coolant bypass hose to the thermostat housing.
l Loosely install the 5 bolts and the 5 stud bolts.
6. Use the Front Cover Aligner, align the front cover.

l Tighten the bolts and stud bolts to 19 Nm (168 lb-in).
Fig. 48: Aligning Front Cover Using Front Cover Aligner

7. Install the 5 engine block cradle-to-engine front cover bolts.

8. Connect the CKP sensor and attach the 2 wiring retainers.

9. Install the accessory drive belt idler pulley and the bolt.
10. Connect the lower radiator hose to the coolant pump.

11. Connect the heater hose to the coolant pump.
12. Connect the upper radiator hose.
13. Install the crankshaft front oil seal. For additional information, refer to CRANKSHAFT FRONT SEAL.
14. Fill the engine with clean engine oil.
15. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
TIMING DRIVE COMPONENTS - CAMSHAFT DRIVE CASSETTE, LH
Special Tool(s)
Adapter for 303-564

303-578 (T97T-6256-A)

303-564 (T97T-6256)
Holding Tool, Crankshaft

303-674
Fig. 49: Exploded View Of Camshaft Drive Cassette - LH With Torque Specifications
ITEM DESCRIPTION
1 W520101 Power Steering Pressure (PSP) tube bracket
nut
2 N605784 Power steering pump pulley bolt (3 required)
3 3A733 Power steering pump pulley
4 W500213 Suction hose bracket bolt
5 W700839 Power steering pump bolt (3 required)
6 3A674 Power steering pump
7 6K254 Hydraulic chain tensioner
8 6M252 LH hydraulic chain tensioner washer
9 6M276 Camshaft sprocket bolt

10 6M276 Jackshaft sprocket bolt
11 W500011 Jackshaft chain tensioner bolts
12 6M271 Jackshaft chain tensioner
13 - Primary chain and sprocket assembly
14 6U001 LH cassette-to-cylinder head bolt
15 W500110 LH cassette-to-cylinder block bolt
16 6M289 Timing chain and guide assembly
Removal
1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD.
4. Remove the engine front cover. For additional information, refer to ENGINE FRONT COVER.
5. Remove all of the roller followers. For additional information, refer to CAMSHAFT ROLLER
FOLLOWER.

disturbed.
7. Remove the LH hydraulic chain tensioner.
8. Remove the LH camshaft sprocket bolt.

l Install the Camshaft Sprocket Holding Tool and Adapter and tighten to 10 Nm (89 lb-in).
l Remove the LH camshaft sprocket bolt.
Fig. 50: Removing LH Camshaft Sprocket Bolt

9. Using the Crankshaft Holding Tool, prevent the crankshaft from turning, remove the jack shaft sprocket
bolt.
Fig. 51: Removing Jackshaft Sprocket Bolt

10. Remove the 2 bolts and the primary chain tensioner.
Fig. 52: Locating Primary Chain Tensioner Bolts

11. Remove the primary chain and sprockets as an assembly.
Fig. 53: Locating Primary Chain And Sprockets

12. Remove the suction hose bracket bolt.

13. Remove the Power Steering Pressure (PSP) tube bracket nut.
14. Remove the 3 bolts and the power steering pump pulley.
15. Remove the 3 bolts and position the power steering pump aside.
16. Remove the LH cassette upper bolt.
Fig. 54: Locating LH Cassette Upper Bolt

17. Remove the LH cassette lower bolt and the LH cassette.
Fig. 55: Locating LH Cassette Lower Bolt

Installation
NOTE: The camshaft chain sprockets must be oriented correctly.
Fig. 56: Locating Camshaft Chain Sprockets

1. Position the LH cassette.

2. Install the LH cassette lower bolt.

3. Install the LH cassette upper bolt.


4. Position the power steering pump and install the 3 bolts.

5. Install the power steering pump pulley and the 3 bolts.

6. Install the PSP tube bracket nut.

7. Install the suction hose bracket bolt.

8. Install the primary chain and sprockets as an assembly.
Fig. 59: Locating Primary Chain And Sprockets

9. Install the jack shaft chain tensioner and the 2 bolts.

Fig. 60: Locating Jackshaft Chain Tensioner Bolts

10. Using the Crankshaft Holding Tool, prevent the crankshaft from turning, tighten the jack shaft sprocket
bolt in 2 stages.
Fig. 61: Tightening Jackshaft Sprocket Bolt

11. Loosely install the camshaft sprocket bolt.

12. Install the engine front cover. For additional information, refer to ENGINE FRONT COVER.

disturbed.
NOTE: The LH hydraulic chain tensioner will be installed during camshaft timing.
13. Retime the LH and RH camshafts. For additional information, refer to CAMSHAFT TIMING.
FOLLOWER.
15. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD.
16. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
TIMING DRIVE COMPONENTS - CAMSHAFT DRIVE CASSETTE, RH
NOTE: For Timing Drive Components - Camshaft Drive Cassette, RH service

information, see Engine under DISASSEMBLY.
TIMING DRIVE COMPONENTS - HYDRAULIC CHAIN TENSIONER, LH
Fig. 62: Identifying Hydraulic Chain Tensioner And Hydraulic Chain Tensioner Washer With Torque
Specification - LH
ITEM DESCRIPTION
1 6K254 LH hydraulic chain tensioner
2 6M252 LH hydraulic chain tensioner
washer
Removal and Installation
1. Remove the Engine Coolant Temperature (ECT) sensor. For additional information, refer to
ELECTRONIC ENGINE CONTROLS .

l To install, tighten to 44 Nm (32 lb-ft).
3. Remove and discard the washer.

4. To install, reverse the removal procedure.
TIMING DRIVE COMPONENTS - HYDRAULIC CHAIN TENSIONER, RH
Fig. 63: Identifying Hydraulic Chain Tensioner And Hydraulic Chain Tensioner Washer With Torque
Specification - RH
ITEM DESCRIPTION
1 6K254 RH hydraulic chain tensioner
2 6M252 RH hydraulic chain tensioner
washer
1. Remove the RH hydraulic chain tensioner.

2. Remove and discard the washer.

VALVE TRAIN COMPONENTS - EXPLODED VIEW
RH Side
Fig. 64: Exploded View Of Valve Train Components - RH With Torque Specifications
ITEM DESCRIPTION
2 6M252 RH hydraulic chain tensioner washer
3 6529 Camshaft roller follower (6 required)
4 6C501 Hydraulic lash adjuster (6 required)
5 6518 Valve spring retainer key (12
required)
6 6A536 Valve spring retainer (6 required)

7 6513 Valve spring (6 required)
8 6571 Valve seal (6 required)
9 6M276 RH camshaft sprocket bolt
10 6256 RH camshaft sprocket
11 W702341 Camshaft bearing cap bolt (8
required)
12 6A258 Camshaft bearing cap (4 required)
13 6250 RH camshaft
LH Side
Fig. 65: Exploded View Of Valve Train Components - LH With Torque Specifications
ITEM DESCRIPTION
2 6M252 LH hydraulic chain tensioner washer
3 6529 Camshaft roller follower (6 required)
5 6518 Valve spring retainer key (12 required)
9 6M276 LH camshaft sprocket bolt
10 6M267 LH camshaft sprocket
11 W702341 Camshaft bearing cap bolt (8 required)
13 6A274 LH camshaft
CAMSHAFTS
Special Tool(s)
Adapter for 303-564

303-578 (T97T-6256-A)

303-564 (T97T-6256-B)

303-565 (T97T-6256-G)

303-573 (T97T-6303-A)

303-575 (T97T-6256-F)
Material
Item Specification
WSS-M2C929-
A
Removal
Both sides
FOLLOWER.
NOTE: The RH and LH camshaft timing procedure must be carried out when
either camshaft is serviced.
2. Rotate the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).

should contact the engine block. This positions the piston at TDC .

RH side
4. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head and tighten
the top 2 clamp bolts to 10 Nm (89 lb-in).
Fig. 67: Locating Camshaft Sprocket Holding Tool, Adapter With Clamp Bolts
NOTE: The RH camshaft sprocket is a LH-threaded bolt.
5. Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket 303-565, loosen the camshaft
sprocket bolt.
6. Remove the camshaft sprocket bolt and position the RH camshaft sprocket aside.
Fig. 69: Locating RH Camshaft Sprocket

LH side
7. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH camshaft and tighten the
2 top clamp bolts to 10 Nm (89 lb-in).

8. Loosen the bolt.
Fig. 71: Locating Camshaft Sprocket Bolt

9. Remove the bolt and position the LH camshaft sprocket aside.
Fig. 72: Locating Camshaft Sprocket

Both sides
NOTE: Mark the position of the camshaft bearing caps so they can be installed in
their original positions.
Fig. 73: Identifying Camshaft Bearing Caps Bolts Removal Sequence

10. Remove the bolts in the sequence shown in illustration and remove the camshaft bearing caps.
11. Remove the camshaft.
Installation
Both sides
NOTE: Lubricate the camshafts with clean engine oil.
1. Install the camshaft.
NOTE: Lubricate the camshaft bearing caps with clean engine oil.
NOTE: The camshaft bearing caps must be installed in their original positions.
NOTE: After installing the bolts, check the camshaft for free rotation.
2. Install the camshaft bearing caps and the bolts.

l Tighten the bolts in the sequence shown in illustration in 2 stages.
Fig. 74: Identifying Camshaft Bearing Caps Bolts Tightening Sequence

RH side
NOTE: The camshaft gear must turn freely on the camshaft. Do not tighten the
bolt at this time.

3. Install the RH camshaft sprocket and loosely install the bolt.
LH side
bolt at this time.

4. Install the LH camshaft sprocket and loosely install the bolt.
Both sides
5. Retime the camshafts. For additional information, refer to CAMSHAFT TIMING.

FOLLOWER.
CAMSHAFT ROLLER FOLLOWER
Special Tool(s)
Compressor, Valve Spring

303-581 (T97T-6565-A)
Material
Item Specification
WSS-M2C929-
A
1. Remove the fuel rail. For additional information, refer to FUEL CHARGING & CONTROLS - 4.0L
SOHC .
2. Remove the LH and RH valve covers. For additional information, refer to VALVE COVER - RH and
VALVE COVER - LH.
3. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Fig. 77: Locating Cam Lobe

NOTE: Mark the position of the camshaft roller followers so they can be installed
in their original positions.
Fig. 78: Removing Camshaft Roller Using Special Tool

4. Using the Valve Spring Compressor, remove the camshaft roller followers.
NOTE: The camshaft roller followers must be installed in their original positions.
NOTE: Lubricate the camshaft roller followers with clean engine oil.
HYDRAULIC LASH ADJUSTER
Material
Item Specification
WSS-M2C929-
A
FOLLOWER.
NOTE: Mark the position of the hydraulic lash adjusters so they can be installed
in their original positions.
2. Remove the hydraulic lash adjusters.
NOTE: The hydraulic lash adjusters must be installed in their original positions.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
VALVE SPRING, RETAINER, AND SEAL
Special Tool(s)

303-581 (T97T-6565-A)
Installer, Valve Stem Oil Seal

303-370 (T90T-6571-A)
Material
Item Specification
WSS-M2C929-
A
Removal
1. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 4.0L SOHC .
FOLLOWER.
3. Position the piston of the cylinder being serviced at Top Dead Center (TDC).
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss
of air pressure will allow the valve to fall into the cylinder. If air pressure
must be removed, support the valve prior to removal.
4. Hold the valves in the cylinder head.

l Use a suitable tool to apply air pressure to the cylinder.
5. Using the Valve Spring Compressor, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Fig. 79: Removing/Installing Valve Spring, Valve Spring Retainer And Retainer Keys
6. Remove the valve seals.
Installation
NOTE: Lubricate the valve seals with clean engine oil.
Fig. 80: Installing Valve Stem Seal Using Valve Stem Seal Installer
1. Using the Valve Stem Oil Seal Installer, install the valve seal.
NOTE: Lubricate the valve springs, retainers and retainer keys with clean engine
oil.
2. Using the Valve Spring Compressor, install the valve springs the valve spring retainers and the valve
spring retainer keys.
FOLLOWER.
4. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 4.0L SOHC .
CYLINDER HEAD
Special Tool(s)
Adapter for 303-564

303-578 (T97T-6256-A)
Adapter for 303-577

303-576 (T97T-6256-D)

303-577 (T97T-6256-C)

303-564 (T97T-6256-B)
Remover, Spark Plug Wire

303-106 (T74P-6666A)

303-565 (T97T-6256-G)

303-571 (T97T-6K254-A)

303-573 (T97T-6303-A)

303-575 (T97T-6256-F)
Material
Item Specification
-
ZC-31-A
WSS-M2C929-
A
XG-3-A A
-
ZC-30
Removal

failure.
Both sides
LIFTING .
INFORMATION .
3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
4. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD.
5. Remove the hydraulic lash adjusters. For additional information, refer to HYDRAULIC LASH
ADJUSTER.
6. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
Fig. 82: Rotating Accessory Drive Belt Tensioner Counterclockwise

RH side
7. Remove the 2 coolant tube bracket bolts.
Fig. 83: Locating Coolant Tube Bracket Bolts

8. Disconnect the generator electrical connector, remove the nut and detach the B+ terminal.
l Detach the pin-type retainer.
Fig. 84: Locating Generator Electrical Connector And Pin-Type Retainer

9. Remove the bolt and the accessory drive belt tensioner.
Fig. 85: Locating Accessory Drive Belt Tensioner Bolt

10. Remove the nut, the 2 bolts and the generator mounting bracket assembly.
Fig. 86: Locating Generator Mounting Bracket Assembly Bolts And Nut
11. Disconnect the heater hose from the thermostat housing.
Fig. 87: Locating Heater Hose On Thermostat Housing

12. Disconnect the upper radiator hose.
Fig. 88: Locating Upper Radiator Hose

13. Position the coolant bypass hose clamp aside.
Fig. 89: Locating Coolant Bypass Hose Clamp

14. Remove the 3 bolts and the thermostat housing.

l Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
Fig. 90: Locating Thermostat Housing

LH side
15. Remove the bolt and the oil level indicator tube.
Fig. 91: Locating Oil Level Indicator Tube And Bolt

16. Remove the stud bolt and detach the ground strap.
l Position the ground strap aside.
Fig. 92: Locating Stud Bolt And Ground Strap

17. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive
(FEAD) bracket.
Fig. 93: Locating Power Steering Supply Hose Bracket

18. Remove the bolt and detach the Power Steering Pressure (PSP) tube bracket from the crossmember.
Fig. 94: Locating Power Steering Pressure (PSP) Tube Bracket On Crossmember
Fig. 95: Locating Power Steering Pump Pulley With Mounting Bolts
Fig. 96: Locating Power Steering Pump Bolts

21. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
Fig. 97: Locating Front Engine Accessory Drive (FEAD) Bracket Bolts And Nut
22. Remove the bolt and detach the starter motor wiring retainer bracket.
Fig. 98: Locating Starter Motor Wiring Retainer Bracket

23. Remove the ground strap bolt and detach the wiring harness retainer from the backside of the cylinder
head.
Fig. 99: Locating Wiring Harness Retainer

Both sides
NOTE: It is important to twist the spark plug wire boots while pulling upward to
avoid possible damage to the spark plug wires.
Fig. 100: Disconnecting Spark Plug Wires From Spark Plugs

24. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs.
25. Remove the 4 bolts and the fuel rail and injectors.
Fig. 101: Locating Fuel Rail And Injectors With Mounting Bolts
26. Separate the 6 fuel injectors from the fuel rail and discard the O-ring seals.
NOTE: LH side shown, RH side similar.
27. Remove the 4 catalytic converter-to-manifold nuts.

l Discard the nuts.
Fig. 102: Locating Catalytic Converter-To-Exhaust Manifold Nuts

28. Remove the 12 nuts and the exhaust manifolds and gaskets.
l Discard the nuts and gaskets.
Fig. 103: Locating Exhaust Manifold Nut

Fig. 104: Locating Exhaust Manifold Studs (LH)

29. Remove and discard the 12 exhaust manifold studs.
RH side
30. Remove the RH side hydraulic chain tensioner.

Fig. 105: Locating Hydraulic Chain Tensioner (RH)

31. Install the Camshaft Sprocket Holding Tool and Adapter.

l Tighten the top clamp bolts to 10 Nm (89 lb-in).
Fig. 106: Locating Camshaft Sprocket Holding Tool And Adapter

32. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, remove the RH
camshaft bolt.
33. Remove the RH side cassette bolt.
Fig. 108: Locating RH Side Cassette Bolt

NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to
remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal
and to prevent the timing chain from falling into the cylinder block.
Fig. 109: Locating Camshaft Sprocket (RH)

34. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and
the timing chain.
LH side
35. Remove the LH side hydraulic chain tensioner.

Fig. 110: Locating LH Hydraulic Chain Tensioner

36. Install the Camshaft Sprocket Holding Tool and Adapter.


37. Remove the LH side camshaft sprocket bolt.

38. Remove the LH side cassette bolt.

Fig. 114: Identifying Rubber Band Around Cassette And Timing Chain
39. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and
the timing chain.
Both sides
NOTE: To avoid damage to the timing chain cassette, an assistant will be required
to help lift the cylinder head from the vehicle.
NOTE: On the RH side, when lifting the cylinder head, be careful to avoid
contacting the A/C tube.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield
design and cannot be reused.
40. Remove the cylinder heads.

l Remove the cylinder head bolts in the sequence shown in illustration. Discard all the bolts.
l Remove and discard the head gaskets.
Fig. 115: Identifying Cylinder Head Bolts Removing Sequence

NOTE: Make sure all coolant residue and foreign material are cleaned from the
block surface and cylinder bore. Failure to follow these instructions may
result in engine damage.
abrasive means to clean the sealing surfaces. These tools cause scratches
and gouges that make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.
NOTE: Observe all warnings and cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal
surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.
41. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
42. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and
the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
Installation
Both sides
1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
2. Position the cylinder head gaskets on the block.
Fig. 116: Locating Cylinder Head Gasket

RH side
to help position the cylinder head in the vehicle.
3. Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in illustration
in 2 stages.
Fig. 117: Identifying RH Cylinder Head Bolts Tightening Sequence

4. Install 2 new M8 bolts.

Fig. 118: Locating M8 Bolts

5. Tighten the 8 M12 bolts in the sequence shown in illustration in 2 stages.

l Stage 1: Tighten 90 degrees.
Fig. 119: Identifying 8 M12 Cylinder Head Bolts Tightening Sequence

bolt at this time.
NOTE: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

6. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
7. Install the RH side cassette bolt.
Fig. 121: Locating RH Side Cassette Bolt

LH side
8. Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in illustration
in 2 stages.


Fig. 123: Locating M8 Bolts


bolt at this time.

11. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
12. Install the LH side cassette bolt.

Both sides
13. Install the 12 exhaust manifold studs.


14. Position new gaskets and the exhaust manifolds. Install the 12 new nuts.

NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
Fig. 129: Locating Spark Plug Wires

15. Connect the 6 spark plug wires to the spark plugs.
16. Install the 4 new catalytic converter-to-exhaust manifold nuts.


NOTE: Lubricate the new O-ring seals with clean engine oil.
17. Install the 6 fuel injectors.

l Install new O-ring seals on the injectors.
l Install the injectors.
18. Position the fuel rail and injectors and install the 4 bolts.
Fig. 131: Locating Fuel Rail And Injectors With Mounting Bolts

disturbed.

wheel and incorrect timing to the engine.

NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Fig. 133: Locating Camshaft Sprocket Holding Tool And Adapter

21. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
Fig. 134: Identifying Camshaft Holding Tool And Adapter On Front Of Cylinder Head (RH)
22. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft
Holding Tool and Adapter, and install the Camshaft Holding Tool and Adapters on the front of the RH
cylinder head.

24. Tighten the 2 top Camshaft Sprocket Holding Tool bolts to 10 Nm (89 lb-in).
Fig. 136: Locating Camshaft Sprocket Holding Tool Clamp Bolts

25. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the
camshaft bolt to 85 Nm (63 lb-ft).
26. Install a new washer and the RH camshaft tensioner.

27. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
Fig. 140: Identifying Camshaft Holding Tool And Adapter On Rear Of Cylinder Head (LH)
28. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapters, and
install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.


1. Tighten the Camshaft Sprocket Holding Tool top 2 bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft sprocket bolt to 85 Nm (63 lb-ft).

31. Install a new washer and the LH camshaft tensioner.


LH side
32. Position the ground strap and install the bolt.

l Attach the wiring harness retainer to the backside of the cylinder head.
Fig. 144: Locating Wiring Harness Retainer

33. Position the starter motor wiring retainer bracket and install the bolt.
Fig. 145: Locating Starter Motor Wiring Retainer Bracket

34. Position the FEAD bracket and A/C compressor. Install the 3 bolts and the nut.

36. Position the power steering pump pulley and install the 3 bolts.
37. Attach PSP tube bracket to the crossmember and install the bolt.
38. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt.

39. Position the ground strap and install the stud bolt.

40. Install the oil level indicator tube and bolt.


RH side
NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
41. Position the thermostat housing and install the 3 bolts.

Fig. 153: Locating Thermostat Housing

42. Position the coolant bypass hose clamp and connect the ECT sensor electrical connector.
Fig. 154: Locating Coolant Bypass Hose Clamp

43. Install the upper radiator hose.
Fig. 155: Locating Upper Radiator Hose

44. Connect the heater hose to the thermostat housing.
Fig. 156: Locating Heater Hose On Thermostat Housing

45. Position the generator mounting bracket assembly and install the 2 bolts and the nut.
Fig. 157: Locating Generator Mounting Bracket Assembly Bolts And Nut
46. Install the accessory drive belt tensioner and bolt.


47. Connect the generator electrical connector. Position the B+ terminal and install the nut.
l Attach the pin-type retainer.
Fig. 159: Locating Generator Electrical Connector And Pin-Type Retainer

48. Install the 2 coolant tube bracket bolts.


Both sides
49. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

50. Install the hydraulic lash adjusters. For additional information, refer to HYDRAULIC LASH
ADJUSTER.
51. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD.
ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW
Steering Gear and Engine Mounts
Fig. 162: Exploded View Of Steering Gear And Engine Mounts With Torque Specifications
ITEM DESCRIPTION
1 N621943 RH engine mount bracket-to-engine mount nut
2 N621943 LH engine mount bracket-to-engine mount nut
3 W704980 Steering column coupling-to-steering gear bolt
4 3B676 Steering column lower shaft
5 W505255 Power Steering Pressure (PSP) tube bracket-to-
crossmember bolt
6 W10909 Steering gear bolts
Oil Pan, Oil Pump, Cylinder Block Cradle and Oil Pump Screen and Pickup Tube
Fig. 163: Exploded View Of Oil Pan, Oil Pump, Cylinder Block Cradle And Oil Pump Screen And
Pickup Tube With Torque Specifications
ITEM DESCRIPTION
7 6730 Oil pan drain plug
8 E802185 Oil pan bolt (10 required)
9 6676 Oil pan
10 6710 Oil pan gasket
11 W500214 Oil pump screen and pickup tube bolt
12 6617 Oil pump screen and pickup tube
13 E804588 Cylinder block cradle bolt

14 W709198 Cylinder block cradle bolt
15 E802185 Bell housing-to-cylinder block cradle spacer bolt (2
required)
16 6C629 Bell housing-to-cylinder block cradle spacer (2
required)
17 E802185 Cylinder block cradle bolt (20 required)
18 E822125 Cylinder block cradle nut (2 required)
19 W702323 Cylinder block cradle bolt (8 required)
20 6734 Washer (2 required)
21 6F092 Cylinder block cradle
22 6710 Cylinder block cradle gasket
23 W708582 Oil pump bolt (2 required)
24 6600 Oil pump
OIL PAN
Material
Item Specification
WSS-M2C929-
A

failure.
LIFTING .
l To install, tighten to 11 Nm (97 lb-in).
3. Remove the 2 power steering gear bolts and position aside the steering gear.
l To install tighten to 115 Nm (85 lb-ft).
Fig. 165: Locating Power Steering Gear Bolts

4. Remove the oil drain plug and drain the engine oil.
5. Remove the bolts, the oil pan and the gasket. Discard the gasket.
abrasive means to clean sealing surfaces. These tools cause scratches
and gouges which make leak paths.
6. Clean and inspect the sealing surfaces.

CYLINDER BLOCK CRADLE
Special Tool(s)
Lifting Bracket, Engine

303-050 (T70P-6000)
Support Bar, Engine

303-F072
Material
Item Specification
-
ZC-31-A
Silicone Gasket and Sealant
WSE-M4G323-A4
TA-30
-
ZC-30
Removal

failure.
LIFTING .
AND CABLES .
3. Remove the Throttle Body (TB). For additional information, refer to FUEL CHARGING &
CONTROLS - 4.0L SOHC .
4. Remove the Front End Accessory Drive (FEAD) bracket bolt and install the Engine Lifting Bracket.
Fig. 166: Locating Engine Lifting Bracket And Front End Accessory Drive (FEAD) Bracket Bolt
5. Remove the 8 pin-type retainers and the radiator sight shield.
Fig. 167: Locating Pin-Type Retainers

6. Install the Engine Support Bar.
Fig. 168: Identifying Engine Support Bar

NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or

equivalent).
Fig. 169: Holding Steering Wheel Using Steering Wheel Holding Device
7. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
8. Remove the RH engine mount nut.
9. Remove the LH engine mount nut.
10. Remove the oil pump screen and pickup tube. For additional information, refer to OIL PUMP SCREEN
AND PICKUP TUBE.
NOTE: Do not allow the steering wheel to rotate while the steering column
intermediate shaft is disconnected or damage to the clockspring can
result. If there is evidence that the wheel has rotated, the clockspring must
be removed and recentered. For additional information, refer to
SUPPLEMENTAL RESTRAINT SYSTEM .
11. Remove the bolt and detach the steering column intermediate shaft from the steering gear.
13. Remove the 2 steering gear-to-crossmember bolts and detach the gear from the crossmember.
14. Remove the starter. For additional information, refer to STARTING SYSTEM .
NOTE: The cylinder block cradle removed for clarity. Note the location of the 2
Torx head bolts at the rear of the cylinder block cradle.
Fig. 170: Locating Cylinder Block Cradle Rear Torx Bolts

15. Remove the 2 cylinder block cradle rear Torx bolts.

16. Remove the 20 bolts and 2 nuts along the outside of the cylinder block cradle.
NOTE: Note the location of the 2 silver-colored bolts that have washer seals. They
must be installed in the same position with new washer seals.
17. Remove the 8 cylinder block cradle inner bolts and the 2 washer seals.
Discard the washer seals.

l
18. Using the Engine Support Bar, raise the engine and then remove the lower block cradle.

Installation
NOTE: Failure to back off the set screws can result in damage to the cylinder
block cradle.
Fig. 172: Locating Cylinder Block Cradle Boss Set Screw

1. Back the set screws off until they are below the cylinder block cradle boss.
and gouges which make leak paths. Use a plastic scraping tool to remove
all traces of old sealant.
NOTE: Gasket material as well as silicone sealant may be present in the cavities
in the main bearing cap. This material must be removed completely prior
to assembly.
Fig. 173: Locating Gasket Mating Surfaces

2. Clean the gasket mating surfaces, making sure all the sealant is removed from the cavities on the rear
main bearing cap. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow
the directions on the packaging.
Fig. 174: Locating Silicone Gasket And Sealant Applying Areas

3. Apply silicone in the 6 places shown in illustration.
4. Position a new gasket and the cylinder block cradle.

5. Install the outer 20 bolts and 2 nuts finger-tight.
6. Install the 2 cylinder block cradle rear Torx bolts finger-tight.
Fig. 175: Locating Cylinder Block Cradle Rear Torx Bolts

7. Install the 2 bellhousing-to-cylinder block cradle bolts.

8. Tighten the outer 20 bolts and 2 nuts.

l Tighten the nuts to 10 Nm (89 lb-in).
l Tighten the bolts to 14 Nm (124 lb-in).
9. Tighten the 2 cylinder block cradle rear Torx bolts.

10. Tighten the 8 inserts.

Fig. 176: Locating Lower Block Cradle Insert

11. Install the 2 silver-colored bolts and new washer seals finger-tight.
Fig. 177: Locating Silver-Colored Bolts

12. Install the 6 remaining inner bolts finger-tight.

13. Tighten the 8 inner bolts in the sequence shown in illustration in 2 stages.
Fig. 178: Identifying Cylinder Block Cradle Inner Bolts Tightening Sequence
14. Install the starter. For additional information, refer to STARTING SYSTEM .
15. Position the steering gear and install the 2 bolts.
16. Attach the PSP tube bracket to the crossmember and install the bolt.
NOTE: Do not allow the steering wheel to rotate while the steering column
intermediate shaft is disconnected or damage to the clockspring can
result. If there is evidence that the wheel has rotated, the clockspring must
be removed and recentered. For additional information, refer to
SUPPLEMENTAL RESTRAINT SYSTEM .
17. Attach the steering column intermediate shaft to the steering gear and install the bolt.
18. Install the oil pump screen and pickup tube. For additional information, refer to OIL PUMP SCREEN
AND PICKUP TUBE.
19. Lower the engine and install the LH engine mount nut.
20. Install the RH engine mount nut.

21. Remove the Engine Lifting Brackets and install the FEAD bracket bolt.
Fig. 179: Locating Engine Lifting Bracket And Front End Accessory Drive (FEAD) Bracket
Bolt
22. Position the radiator sight shield and install the 8 pin-type retainers.

23. Install the TB . For additional information, refer to FUEL CHARGING & CONTROLS - 4.0L SOHC .
24. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
OIL PUMP
1. Remove the cylinder block cradle. For additional information, refer to CYLINDER BLOCK CRADLE.
2. Remove the 2 bolts and the oil pump.
OIL PUMP SCREEN AND PICKUP TUBE
1. Remove the oil pan. For additional information, refer to OIL PAN.
2. Remove the bolt and the oil pump screen and pickup tube.
OIL LEVEL INDICATOR AND TUBE
Material
Item Specification
WSS-M2C929-
A
Fig. 181: Exploded View Of Oil Level Indicator And Tube With Torque Specifications
ITEM DESCRIPTION
1 W500213 Oil level indicator tube bolt
2 6754 Oil level indicator tube
3 - Oil level indicator tube O-ring seal

l Remove and discard the O-ring seal.
NOTE: Lubricate the O-ring seal with clean engine oil.
EXHAUST MANIFOLD - LH
Fig. 182: Exploded View Of Exhaust Manifold - LH With Torque Specifications

ITEM DESCRIPTION
1 W701706 LH catalytic converter-to-exhaust manifold nut (2
required)
2 - EGR system module tube fitting (part of 9E649)
3 W701706 LH exhaust manifold nut (6 required)
4 9431 LH exhaust manifold
5 9448 LH exhaust manifold gasket
6 W705495 LH exhaust manifold stud (6 required)
Removal
LIFTING .
2. Remove the 2 catalytic converter-to-exhaust manifold nuts.
l Discard the nuts.
3. Disconnect the EGR system module tube from the exhaust manifold.
4. Remove the 6 nuts, the LH exhaust manifold and the gasket.
l Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .
6. Remove and discard the 6 LH exhaust manifold studs.
Installation
1. Install the 6 new LH exhaust manifold studs.

2. Install the new LH exhaust manifold gasket, manifold and 6 new nuts.
3. Connect the EGR system module tube to the exhaust manifold.


EXHAUST MANIFOLD - RH
Fig. 183: Exploded View Of Exhaust Manifold - RH With Torque Specifications

ITEM DESCRIPTION
1 W701706 RH catalytic converter-to-exhaust manifold nut (2
required)
2 W701706 RH exhaust manifold nut (6 required)

3 9430 RH exhaust manifold
4 9448 RH exhaust manifold gasket
5 W705495 RH exhaust manifold stud (6 required)
Removal
LIFTING .
l Discard the nuts.
3. Remove the nuts, the RH exhaust manifold and the gasket.

l Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM -
5. Remove and discard the 6 RH exhaust manifold studs.
Installation
1. Install the 6 new RH exhaust manifold studs.

2. Install the new RH exhaust manifold gasket, manifold and 6 new nuts.

ENGINE MOUNT - LH
Special Tool(s)

303-050 (T70P-6000)
Support Bar, Engine

303-F072
Fig. 184: Exploded View Of Engine Mount - LH With Torque Specifications

ITEM DESCRIPTION
1 W710565 LH engine mount bracket bolt (3 required)
2 N621943 LH engine mount bracket-to-engine mount
nut
3 6B033 LH engine mount bracket
4 W707641 LH engine mount bolt (2 required)
5 6038 LH engine mount
LIFTING .
Bolt


6. Remove the engine mount bracket-to-engine mount nut.

7. Remove the 3 engine mount bracket bolts and remove the bracket.
8. Remove the 2 engine mount bolts and the engine mount.

ENGINE MOUNT - RH
Special Tool(s)

303-050 (T70P-6000)
Support Bar, Engine

303-F072
Fig. 188: Exploded View Of Engine Mount - RH With Torque Specifications

ITEM DESCRIPTION
1 W710565 RH engine mount bracket bolt (4 required)
2 N621943 RH engine mount bracket-to-engine mount
nut
3 6037 RH engine mount bracket
4 W707641 RH engine mount bolt (2 required)
5 6038 RH engine mount
LIFTING .
AND CABLES .
Bolt


7. Remove the engine mount-to-engine bracket mount nut.

8. Remove the 4 engine mount bracket bolts and remove the bracket.
9. Remove the 2 engine mount bolts and the engine mount.

REMOVAL
ENGINE
Special Tool(s)

303-050 (T70P-6000)
Remover, Spark Plug Wire

303-106 (T74P-6666A)
Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
Removal
NOTE: Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in
clamp load on the crankshaft pulley and timing sprocket, which could cause
severe engine damage.
All vehicles
LIFTING .
INFORMATION .
3. Disconnect the battery ground and positive cables. For additional information, refer to BATTERY,
MOUNTING AND CABLES .
4. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR
5. Release the 2 windshield washer hose retainers and the one hood insulation pin-type retainer.
Fig. 192: Locating Windshield Washer Hose Retainers And Hood Insulation Pin-Type Retainer
6. Position the hood insulation aside and disconnect the windshield washer hose.
Fig. 193: Locating Windshield Washer Hose

NOTE: Index-mark the hood hinge location to aid in hood installation.
7. Remove the 4 bolts and the hood.

8. Drain the cooling system. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
Vehicles with automatic transmission
9. Remove the transmission. For additional information, refer to AUTOMATIC

Vehicles with manual transmission
10. Remove the clutch. For additional information, refer to CLUTCH .
All vehicles
11. Disconnect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical
connectors.
Fig. 194: Locating Heated Oxygen Sensor (HO2S) Electrical Connector


l Discard the nuts.

13. Remove the stud bolt and detach the ground strap.
l Position the ground strap aside.

14. Remove the oil pan drain plug and drain the engine oil.
l Install the drain plug and tighten to 26 Nm (19 lb-ft).
15. Disconnect the upper radiator hose from the thermostat housing.
Fig. 197: Locating Upper Radiator Hose On Thermostat Housing

16. Disconnect the lower radiator hose from the coolant pump.
Fig. 198: Locating Lower Radiator Hose On Coolant Pump

17. Remove the nut and Power Steering Pressure (PSP) tube bracket from the A/C compressor.
Fig. 199: Identifying Power Steering Pressure (PSP) Tube Bracket Nut
18. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive
(FEAD) bracket.

19. Disconnect the PSP switch electrical connector.
Fig. 201: Locating Power Steering Pressure (PSP) Switch Electrical Connector
20. Disconnect the A/C compressor and A/C high pressure switch electrical connectors.
Fig. 202: Locating A/C Compressor And A/C High Pressure Switch Electrical Connectors
21. Detach the 2 wiring retainers from the FEAD bracket.
Fig. 203: Locating Wiring Retainers On FEAD Bracket

22. Disconnect the fuel supply tube coupling. For additional information, refer to FUEL SYSTEM -
Fig. 204: Locating Fuel Supply Tube Coupling

23. Loosen the 3 bolts on the power steering pump pulley.
24. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.


27. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
28. Disconnect the 2 heater hoses from the coolant tube.
Fig. 210: Locating Heater Hoses On Coolant Tube

29. Remove the 2 coolant tube bracket bolts.

NOTE: When removing the ignition wires, a slight twisting motion will break the
seal and ease removal.
30. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs.
l Detach the retainers from the valve cover stud bolts and the ignition coil bracket.
Fig. 212: Disconnecting Spark Plug Wires From Spark Plugs

31. Detach the spark plug wire retainer from the intake manifold.
Fig. 213: Locating Spark Plug Wire Retainer On Intake Manifold

32. Disconnect the radio ignition interference capacitor electrical connector.
Fig. 214: Locating Radio Ignition Interference Capacitor Electrical Connector

33. Disconnect the ignition coil electrical connector.
Fig. 215: Locating Ignition Coil Electrical Connector

34. Remove the 2 upper ignition coil bracket bolts.
Fig. 216: Locating Upper Ignition Coil Bracket Bolts

35. Remove the 2 lower ignition coil bracket bolts and then remove the ignition coil and spark plug wires.
Fig. 217: Locating Ignition Coil Bracket Bolts

36. Detach the crankcase vent tube from the LH valve cover and remove the tube.
Fig. 218: Locating Crankcase Vent Tube

37. Disconnect the brake booster vacuum hose from the upper intake manifold.
Fig. 219: Locating Brake Booster Vacuum Hose On Upper Intake Manifold
38. Disconnect the fuel vapor vent tube from the intake manifold.
Fig. 220: Locating Fuel Vapor Vent Tube To Intake Manifold

39. Disconnect the upper and lower PCM electrical connectors.
Fig. 221: Locating Upper And Lower Powertrain Control Module (PCM) Electrical Connectors
40. Disconnect the 16-pin electrical connector and detach the 2 wiring retainers.
Fig. 222: Locating 16-Pin Electrical Connector With Wiring Retainers

41. Detach the 3 wiring harness retainers.
Fig. 223: Locating Wiring Harness Retainers

42. Remove the Power Distribution Box (PDB) cover.

43. Remove the bolt and detach the B+ terminal from the PDB .
l Detach the pin-type retainer from the strut tower.
Fig. 224: Locating Pin-Type Retainer

44. Detach the PDB upper housing from the lower housing, loosen the bolt and then disconnect the 68-pin
connector from the PDB .
Fig. 225: Locating Power Distribution Box Upper Housing With Mounting Bolt
45. Remove the bolt and detach the ground cable from the RH strut tower.
Fig. 226: Locating Ground Cable With Mounting Bolt

46. Detach the battery cable harness pin-type retainer from the cowl.
Fig. 227: Locating Battery Cable Harness Pin-Type Retainer

47. Install the Engine Lifting Bracket to the RH cylinder head.
Fig. 228: Identifying Engine Lifting Bracket On RH Cylinder Head

48. Install the Engine Lifting Bracket to the LH cylinder head.
Fig. 229: Identifying Engine Lifting Bracket On LH Cylinder Head

49. Remove the LH engine mount nut.
Fig. 230: Locating Engine Mount Nut (LH)

50. Remove the RH engine mount nut.
Fig. 231: Locating Engine Mount Nut (RH)

51. Using the Engine Lifting Bracket and Spreader Bar, remove the engine.
Fig. 232: Identifying Engine Lifting Bracket And Spreader Bar On Engine
DISASSEMBLY
ENGINE
Special Tool(s)
Adapter for 303-564

303-578 (T97T-6256-A)

303-581 (T97T-6565-A)

303-564 (T97T-6256-B)
Remover, Crankshaft Front Oil Seal

303-107 (T74P-6700-A)
303-101 (T74P-3616-A)

303-773
Socket, Rear Jack Shaft

303-634
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
General Equipment
GENERAL EQUIPMENT CHART

8 mm x 1.25 x 100 mm bolts (2 required)
Material
Item Specification
-
ZC-31-A
-
ZC-30
All vehicles

failure.
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so
may result in engine damage.
NOTE: If the fuel rail is used as a leverage device, damage may occur to the fuel rail.
Care must be taken when working around the fuel rail.
NOTE: For additional information, refer to the exploded views under Engine in
Assembly.
1. Remove the 8 bolts and the flexplate or flywheel.

Fig. 233: Locating Flexplate Or Flywheel With Mounting Bolts

2. Remove the spacer plate and if equipped, the flexplate-to-crankshaft spacer.
Fig. 234: Locating Flexplate-To-Crankshaft Spacer

NOTE: The original crankshaft rear seal does not have a speedy sleeve. Only a
new replacement crankshaft rear seal comes with a speedy sleeve.
NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve
must be removed before engine disassembly.
Fig. 235: Locating Speedy Sleeve

3. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
4. Mount the engine on a suitable engine stand.
5. Disconnect the generator and Throttle Body (TB) electrical connectors.
Fig. 236: Locating Generator And Throttle Body Electrical Connectors

6. Remove the nut and detach the B+ terminal from the generator.
l Detach the wiring retainer from the coolant tube bracket.
Fig. 237: Locating B+ Terminal Nut And Wiring Retainer On Coolant Tube Bracket
7. Disconnect the vacuum tube and the fuel rail pressure and temperature sensor electrical connector.
Fig. 238: Locating Vacuum Tube With Fuel Rail Pressure And Temperature Sensor Electrical
Connector
8. Disconnect the EGR system module and Throttle Position (TP) sensor electrical connectors.
Fig. 239: Locating EGR System Module And Throttle Position (TP) Sensor Electrical Connectors
9. Disconnect the EGR tube fitting from the EGR system module.
Fig. 240: Locating EGR Tube Fitting On EGR System Module

10. Disconnect the EGR tube fitting from the LH exhaust manifold and remove the tube.
Fig. 241: Locating Exhaust Gas Recirculation (EGR) Tube Fitting

11. Disconnect the PCV tube fittings and remove the tube.
Fig. 242: Locating Positive Crankcase Ventilation (PCV) Tube Fittings

12. Disconnect the Knock Sensor (KS) electrical connector and detach the wiring retainer.
Fig. 243: Locating Knock Sensor (KS) Electrical Connector


Fig. 244: Locating Intake Manifold Bolt

13. Remove the 8 bolts and the intake manifold.

14. Remove the 2 fuel supply tube bracket bolts.
Fig. 245: Locating Fuel Supply Tube Bracket Bolts

15. Disconnect the Camshaft Position (CMP) electrical connector.
Fig. 246: Locating Camshaft Position (CMP) Electrical Connector

16. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
Fig. 247: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Retainer
17. Remove the bolt and the accessory drive belt tensioner.

18. Remove the 2 bolts, the nut and the generator and bracket.
Fig. 249: Locating Generator Bracket Bolts And Nut

19. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring retainers.
Fig. 250: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Wiring Retainers
20. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
Fig. 251: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
21. Disconnect the PCV valve electrical connector.
Fig. 252: Locating PCV Valve Electrical Connector

22. Disconnect the 3 LH fuel injector electrical connectors and detach the wiring retainer from the valve
cover stud bolt.
Fig. 253: Locating Fuel Injector Electrical Connectors And Wiring Retainer (LH)
23. Disconnect the 3 RH fuel injector electrical connectors and detach the wiring retainer from the valve
cover stud bolt.
Fig. 254: Locating Fuel Injector Electrical Connectors And Wiring Retainer (RH)
24. Remove the 3 bolts, detach the wiring retainers and remove the main engine wiring harness.
Fig. 255: Locating Main Engine Wiring Harness Bolts

25. Remove the 4 bolts and then remove the fuel rail and injectors.
Fig. 256: Locating Fuel Rail And Injector Bolts

26. Remove the bolt and the KS .
Fig. 257: Locating Knock Sensor Bolt

27. Remove the bolt and then disconnect the coolant bypass hose and the heater hose from the coolant pump.
Fig. 258: Locating Coolant Bypass Hose, Heater Hose With Mounting Bolt
28. Remove the 3 bolts and then remove the thermostat housing, hoses and coolant tube.
Fig. 259: Locating Thermostat Housing Bolts

29. Remove the 3 bolts, 3 stud bolts and the LH valve cover.
Fig. 260: Locating Valve Cover Bolt (LH)

30. Remove the 2 bolts, 4 stud bolts and the RH valve cover.
Fig. 261: Locating Valve Cover Bolt (RH)

l Discard the oil level indicator tube O-ring seal.

32. Remove the 6 nuts and the LH exhaust manifold and gasket.
l Discard the nuts and the LH exhaust manifold gasket.

33. Remove and discard the 6 LH exhaust manifold studs.

34. Remove the 3 bolts and the LH engine mount bracket.
Fig. 265: Locating Engine Mount Bracket Bolts (LH)

35. Remove the 6 nuts and the RH exhaust manifold and gasket.
l Discard the nuts and the RH exhaust manifold gasket.

36. Remove and discard the 6 RH exhaust manifold studs.
Fig. 267: Locating RH Exhaust Manifold Studs

37. Clean and inspect the LH and RH exhaust manifolds. For additional information, refer to ENGINE
SYSTEM - GENERAL INFORMATION .
38. Remove the 4 bolts and the RH engine mount bracket.
Fig. 268: Locating Engine Mount Bracket Bolts (RH)

39. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the upward position.

NOTE: Mark each camshaft roller follower to make sure it is installed in its
original position during reassembly.
Fig. 270: Removing Camshaft Roller Follower Using Valve Spring Compressor
40. Using the Valve Spring Compressor, remove the camshaft roller followers.
NOTE: Mark each hydraulic lash adjuster to make sure it is installed in its original
position.
Fig. 271: Locating Hydraulic Lash Adjuster Nut

41. Remove the hydraulic lash adjusters.

42. Remove the RH hydraulic chain tensioner.
Fig. 272: Locating RH Hydraulic Chain Tensioner

43. Install the Camshaft Sprocket Holding Tool and Adapter on the RH cylinder head and tighten the top 2
clamp bolts to 10 Nm (89 lb-in).

Fig. 274: Locating RH Camshaft Sprocket Bolt

44. Remove the RH camshaft sprocket bolt.

45. Remove the RH cassette bolt.
Fig. 275: Locating RH Cassette Bolt

46. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and
the timing chain.
Fig. 277: Locating LH Hydraulic Chain Tensioner

48. Install the Camshaft Sprocket Holding Tool and Adapter on the LH cylinder head and tighten the top 2
clamp bolts to 10 Nm (89 lb-in).

49. Remove the LH camshaft sprocket bolt.

50. Remove the LH cassette bolt.

51. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and
the timing chain.
52. Remove the bolts in the sequence shown in illustration and remove the cylinder heads.
l Discard the gaskets and the bolts.
Fig. 282: Identifying Cylinder Head Bolts Removing Sequence

NOTE: Make sure all coolant residue and foreign material are cleaned from the
block surface and cylinder bore. Failure to follow these instructions may
result in engine damage.
and gouges that make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.
NOTE: Observe all warnings and cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal
surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.
53. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remove with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
54. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and
the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
55. Remove the 2 bolts and the CKP .
Fig. 283: Locating Crankshaft Position (CKP) Sensor Bolts

56. Using the Strap Wrench, hold the crankshaft pulley, remove the bolt and washer.

NOTE: If the pulley bolt is not installed, the Crankshaft Vibration Damper
Removers will bottom out before the pulley is off.
57. Install the crankshaft pulley bolt 2 to 3 turns. Using the Crankshaft Vibration Damper Removers and the
two 8-mm bolts, remove the crankshaft pulley.
l Discard the crankshaft pulley bolt.
Fig. 285: Removing Crankshaft Pulley

58. Remove the 4 bolts and the coolant pump pulley.
Fig. 286: Locating Coolant Pump Pulley Bolt

59. Remove the 13 bolts and the coolant pump.
Fig. 287: Locating Coolant Pump Bolts

60. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
Fig. 288: Locating Crankshaft Front Oil Seal And Crankshaft Front Oil Seal Remover
61. Remove the 5 cylinder block cradle-to-engine front cover bolts.
Fig. 289: Locating Cylinder Block Cradle-To-Engine Front Cover Bolt

62. Remove the 5 bolts, 5 stud bolts and the engine front cover.
Fig. 290: Locating Engine Front Cover Bolts

63. Remove and discard the engine oil filter.
Fig. 291: Locating Engine Oil Filter

64. Remove the bolts and the oil pan.
Fig. 292: Locating Oil Pan Bolt

65. Remove the bolt and the oil pump screen cover and tube.
Fig. 293: Locating Oil Pump Screen Cover And Tube

NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These
bolts must be installed in the same position from which they were
removed with new washer seals.
Fig. 294: Locating Cylinder Block Cradle Inner Bolt
66. Remove the 8 cylinder block cradle inner bolts. Remove and discard the 2 washer seals.
67. Remove the 2 cylinder block cradle Torx bolts.
Fig. 295: Locating Cylinder Block Cradle Torx Bolts

68. Remove the 15 bolts and the 2 nuts.

l Remove the cylinder block cradle.
Fig. 296: Locating Cylinder Block Cradle Bolts And Nuts

69. Remove the 2 bolts, the oil pump pickup tube and the oil pump intermediate shaft.
Fig. 297: Locating Oil Pump Intermediate Shaft, Oil Pump Pickup Tube With Bolts
70. Remove the oil filter adapter.
Fig. 298: Locating Oil Filter Adapter

71. Remove the 2 bolts and the jack shaft chain tensioner.
Fig. 299: Locating Jackshaft Chain Tensioner Bolts

72. Remove the 2 bolts and the jack shaft chain guide.
Fig. 300: Locating Jackshaft Chain Guide Bolts

73. Remove the jack shaft rear plug.
Fig. 301: Locating Jackshaft Rear Plug

74. Install the Rear Jack Shaft Socket on the rear of the jack shaft.
Fig. 302: Identifying Rear Jack Shaft Socket On Rear Of Jackshaft

75. Using the Rear Jack Shaft Socket to hold the jack shaft, loosen the jack shaft sprocket bolt.
Fig. 303: Locating Jackshaft Sprocket Bolt

76. Using the Rear Jack Shaft Socket to hold the jack shaft, loosen the rear jack shaft sprocket bolt.
Fig. 304: Holding Jackshaft Using Rear Jack Shaft Socket

NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12
external Torx socket, in order to remove the bolt if the bolt does not turn
out easily at this time.

77. Remove the jack shaft sprocket bolt.

78. Remove the jack shaft and crankshaft sprockets and the chain.
l Remove the crankshaft key.
Fig. 306: Locating Jackshaft, Crankshaft Sprockets And Chain

79. Remove the bolt and the LH camshaft drive cassette.

80. Remove the RH camshaft drive cassette bolt and spacer.
Fig. 308: Locating RH Camshaft Drive Cassette Bolt

NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12
external Torx socket, in order to remove the bolt if the bolt does not turn
out easily at this time.
Fig. 309: Locating Rear Jackshaft Sprocket Bolt

81. Remove the rear jack shaft sprocket bolt and remove the RH camshaft drive cassette.
82. Remove the bolt, the hold down and the oil pump drive.
Fig. 310: Locating Oil Pump Drive Bolt

83. Remove the 2 bolts and the jack shaft thrust plate.
Fig. 311: Locating Jackshaft Thrust Plate Bolts

84. Remove the jack shaft.
Fig. 312: Removing/Installing Jackshaft

85. Remove the jack shaft spacer.
Fig. 313: Locating Jackshaft Spacer

86. Using the Crankshaft Holding Tool, loosen the front sprocket retaining bolt.
Fig. 314: Loosening Front Sprocket Retaining Bolt Using Crankshaft Holding Tool
87. Remove the bolts and the chain tensioner.
Fig. 315: Locating Chain Tensioner Bolts

88. Remove the chain guide.
Fig. 316: Locating Chain Guide Bolts

89. Remove the bolt.

90. Remove the jack shaft sprocket and chain.
Fig. 318: Locating Chain And Jackshaft Sprocket

91. Remove the LH cassette bolt.

92. Remove the LH cassette.
93. Remove the jack shaft thrust plate.

94. Remove the jack shaft.

Vehicles equipped with a balance shaft
95. Remove the balance shaft tensioner.
1. Install a pin in the balance shaft tensioner.

2. Remove the 2 bolts.
3. Remove the balance shaft tensioner.
Fig. 323: Removing Balance Shaft Tensioner

96. Remove the 2 bolts and the balance shaft chain guide.
NOTE: DO NOT remove the balance shaft sprocket bolt.
Fig. 324: Locating Balance Shaft Chain And Crankshaft Sprocket

97. Remove the balance shaft chain and crankshaft sprocket.

98. Remove the balance shaft.
1. Remove the 2 bolts.
2. Remove the balance shaft.
Fig. 325: Identifying Balance Shaft With Mounting Bolts

All vehicles
99. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's
instructions.
NOTE: Clearly mark the connecting rods and rod caps in numerical order for
correct reassembly.
100. Remove the connecting rod caps.

1. Remove the connecting rod nuts.
2. Remove the connecting rod caps.
Fig. 326: Identifying Connecting Rod Nuts And Caps

101. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
Fig. 327: Locating Rubber Hose Pieces On Crankshaft Bolts

102. Remove the connecting rod bearings.
Fig. 328: Removing Connecting Rod Bearings

103. Remove the piston rings.
Fig. 329: Locating Piston Rings

104. Clean and inspect the pistons. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do
so can result in engine damage.
NOTE: Number (or mark) the crankshaft bearing caps before removing them.
Fig. 330: Locating Crankshaft Main Bearing Cap Bolts

105. Remove the bolts and the crankshaft main bearing caps.
106. Remove the crankshaft rear oil seal from the crankshaft.
Fig. 331: Locating Crankshaft Rear Oil Seal

107. Remove the crankshaft.
Fig. 332: Locating Crankshaft

108. Remove the crankshaft main bearings and the thrust bearing.
Fig. 333: Locating Crankshaft Main Bearings And Thrust Bearing

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

CYLINDER HEAD
Special Tool(s)

303-581 (T97T-6565-A)
Installer, Valve Stem Oil Seal

303-370 (T90T-6571-A)
Material
Item Specification
WSS-M2C929-
A
Fig. 334: Exploded View Of Cylinder Head With Torque Specifications

ITEM DESCRIPTION
1 12405 Spark plugs
6 6505 Exhaust valve (3 required)
7 6507 Intake valve (3 required)
8 W702341 Camshaft bearing cap mounting bolt (8
required)
11 6050 LH cylinder head
Disassembly
NOTE: Only use hand tools when removing or installing the spark plugs, damage
may occur to the cylinder head or spark plug.
1. Remove the spark plugs.
NOTE: Keep the valves, valve springs, retainers and retainer keys in order so they
can be installed in their original positions.
2. Using the Valve Spring Compressor, remove the valve spring retainer keys, the valve spring and the
retainer. Remove the valve.
l Repeat the procedure until all of the valves are removed.
3. Remove and discard the valve seals.
NOTE: Mark the position of the camshaft bearing caps so they can be installed in
their original positions.
Fig. 336: Identifying Camshaft Bearing Caps Bolts Removal Sequence

4. Remove the bolts in the sequence shown in illustration and remove the camshaft bearing caps.
5. Remove the camshaft.
Assembly
NOTE: Lubricate all parts with clean engine oil prior to assembly.
1. Position the camshaft.
NOTE: The camshaft bearing caps must be installed in their original positions.
NOTE: After installing the bolts, check the camshaft for free rotation.
2. Install the camshaft bearing caps and the bolts.

Fig. 337: Identifying Camshaft Bearing Caps Bolts Tightening Sequence

NOTE: Valves must be installed in the positions from which they were removed.
3. Install the valve.

4. Using the Valve Stem Oil Seal Installer, install new valve stem seals.
Fig. 338: Installing Valve Stem Seal Using Valve Stem Seal Installer
NOTE: The valve springs, retainers and retainer keys must be installed in the
positions from which they were removed.
5. Using the Valve Spring Compressor, install the valve spring, the retainer and the retainer keys.
NOTE: Only use hand tools when removing or installing the spark plugs, damage
may occur to the cylinder head or spark plug.
6. Install the spark plugs.

PISTON
Special Tool(s)
Service Set, Piston Pin

303-S024 (T68P-6135-A)
Material
Item Specification
WSS-M2C929-
A
Fig. 340: Exploded View Of Piston

ITEM DESCRIPTION
1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment
ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment
ring
6 6135 Piston pin
7 6200 Connecting rod
8 6110 Piston
Disassembly
NOTE: The connecting rod bolts and nuts cannot be reused.
NOTE: Mark the position of the parts, so they can be installed in their original
positions.
1. Remove the connecting rod bearings from the connecting rod and cap.
2. Remove the piston rings from the piston.
3. Using the Piston Pin Service Set, press the piston pin out of the connecting rod and piston assembly.
Fig. 341: Identifying Piston Pin Service Set

Assembly
NOTE: Lubricate all parts with clean engine oil.
NOTE: Install the piston in the connecting rod with the cylinder number side of the rod
and the indentation notch in the piston on the same side.
NOTE: The oil hole in the connecting rod must face the RH side of the cylinder block
and the arrow on the piston must face the front of the engine block.
NOTE: If the piston pin is removed from the piston, a new piston and piston pin
must be used. Do not reuse the piston or the piston pin.
1. Gradually heat the pin bore side of the connecting rod to approximately 232°C-316°C (467°F-626°F) and
immediately install the piston pin.
2. Using the Piston Pin Service Set, press the piston pin into the piston and connecting rod assembly.
Fig. 342: Identifying Piston Pin Service Set

3. Install the piston rings.
4. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the
circumference of the piston.
Fig. 343: Identifying Piston Ring Gap Position

5. Install the connecting rod bearings in the connecting rod and cap.
ASSEMBLY
ENGINE
Special Tool(s)
Adapter for 303-564

303-578 (T97T-6256-A)
Adapter for 303-577

303-576 (T97T-6256-D)
Adapter for 303-579 (part of 303-S524)

303-527 (T95P-6701-A3)

303-093 (T74P-6019-A)
Compressor, Piston Ring

303-D032 (D81L-6002-C)

303-581 (T97T-6565-A)

303-577 (T97T-6256-C)

303-564 (T97T-6256-B)
Holding Tool, Crankshaft

303-674
Installer, Crankshaft Rear Oil Seal

303-579 (T97T-6701-A)

303-102 (T74P-6316-B)

303-050 (T70P-6000)
Screws, Crankshaft Rear Oil Seal (part of 303-

S524)
303-528 (T95T-6701-A4)
Socket, Rear Jack Shaft

303-634
Spreader Bar
Strap Wrench
303-D055 (85L-6000-A) or equivalent

303-571 (T97T-6K254-A)

303-573 (T97T-6303-A)
Material
Item Specification
-
ZC-31-A
XO-5W30-QSP (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil CXO- WSS-M2C929-A
5W30-LSP12 (Canada); or equivalent
Silicone Brake Caliper Grease and Dielectric Compound
ESE-M1C171-A
XG-3-A
TA-30 A4
-
ZC-30
TA-24 A2
Upper End
Fig. 344: Identifying Engine Upper End Components

ITEM DESCRIPTION
1 6582 RH valve cover
2 6769 Electric PCV valve
3 9D280 RH fuel rail
4 9F593 Fuel injector (6 required)
5 9G512 Fuel injector insert adapter (6 required)
6 6A258 RH camshaft thrust bearing cap
7 6250 RH camshaft
8 8A586 Thermostat housing
9 9E469 EGR system module tube
10 6K817 PCV tube
11 9K479 Intake manifold

12 9E498 Vacuum harness
13 9E964 Fuel supply tube
14 9G756 Fuel rail pressure and temperature sensor
15 9D280 LH fuel rail
16 6A505 LH valve cover
18 6A258 LH camshaft thrust bearing cap
19 6A258 LH camshaft bearing cap (3 required)
21 6529 Roller follower (12 required)
26 6571 Valve stem seal (12 required)
27 9448 LH exhaust manifold gasket
28 9431 LH exhaust manifold
29 6507 Intake valve (6 required)
30 6083 LH cylinder head gasket
31 6505 Exhaust valve (6 required)
32 12405 Spark plug (6 required)
33 6049 LH cylinder head
34 6049 RH cylinder head
35 6051 RH cylinder head gasket
37 9448 RH exhaust manifold gasket
38 9430 RH exhaust manifold
39 18696 Coolant tube
40 6A258 RH camshaft bearing cap (3 required)
Lower End
Fig. 345: Identifying Engine Lower End Components

ITEM DESCRIPTION
1 6B321 Crankshaft pulley
2 6C315 Crankshaft Position (CKP) sensor
3 8501 Coolant pump
4 6700 Crankshaft front oil seal

5 8507 Coolant pump gasket
6 6019 Engine front cover
7 6020 Engine front cover gasket
8 6M270 Jackshaft chain
9 6M264 Jackshaft chain sprocket
10 6M271 Jackshaft chain tensioner
11 6M272 Jackshaft chain guide
12 6714 Oil filter
13 6884 Oil filter adapter
14 6L621 Oil filter adapter O-ring seal
15 12A699 Knock Sensor (KS)
16 6M290 RH camshaft drive cassette
17 6M289 LH camshaft drive cassette
18 6846 Oil pump drive assembly
19 6754 Oil level indicator tube
20 6750 Oil level indicator
21 6M296 Jackshaft seal
22 6M052 Jackshaft plug
23 6375 Flexplate
24 6434 Flexplate-to-crankshaft spacer
25 6701 Crankshaft rear oil seal
26 9278 Oil pressure sensor
27 6A311 Balance shaft (if equipped)
28 6K355 Balance shaft chain tensioner (if equipped)
29 6A364 Balance shaft chain (if equipped)
30 6375 Flywheel (manual transmission only)
31 6333 Crankshaft main bearing (3 required)
32 6337 Crankshaft main bearing cap
33 W702979 Woodruff key
34 6306 Jackshaft chain sprocket
35 6K350 Balance shaft chain sprocket (if equipped)
36 6A338 Crankshaft main bearing (3 required)
37 6303 Crankshaft
38 6A339 Crankshaft main bearing cap
39 6325 Crankshaft main thrust bearing
40 6A605 Oil pump drive shaft
41 6621 Oil pump
42 6C629 Shim (2 required)
43 6675 Oil pan
44 6617 Oil pump screen and pickup tube
45
6F092 Cylinder block cradle

46 6710 Cylinder block cradle gasket
47 6210 Connecting rod cap
48 6211 Connecting rod bearings
49 6200 Connecting rod
50 6135 Piston pin
51 6159 Oil control rings
52 6152 Lower compression ring
53 6150 Upper compression ring
54 6161 Oil control ring spacer
55 6110 Piston
All vehicles

failure.
NOTE: If the fuel rail is used as a leverage device, damage may occur to the fuel rail.
Care must be taken when working around the fuel rail.
1. Install the crankshaft main bearings and the thrust bearing.

l Lubricate the crankshaft main bearings with clean engine oil.
2. Install the lower main bearings in the bearing caps.
Fig. 346: Locating Crankshaft Main Bearings And Thrust Bearing

NOTE: The crankshaft main bearings are precision selective fit. Inspect the
bearing clearance. For additional information, refer to ENGINE SYSTEM -
Fig. 347: Locating Crankshaft

3. Install the crankshaft.
Failure to follow this procedure may cause future oil leakage.
Fig. 348: Identifying Silicone Gasket And Sealant Applying Areas On Rear Main Bearing Cap To
Cylinder Block Parting Line
4. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
5. Install the main bearing caps in the order in which they were removed.
Fig. 349: Identifying Main Bearing Caps

6. Tighten the bolts in the sequence shown in illustration to 35 Nm (26 lb-ft) and then rotate an additional 57
degrees.
Fig. 350: Identifying Main Bearing Cap Bolts Tightening Sequence

7. Check the piston to cylinder bore and ring clearance. For additional information, refer to ENGINE
NOTE: Lubricate the piston rings with clean engine oil.
8. Install the piston rings.

9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the
circumference of the piston.
Fig. 351: Identifying Piston Ring Gap Position

10. Install the connecting rod bearings.
Fig. 352: Installing Connecting Rod Bearings

11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
Fig. 353: Locating Rubber Hose Pieces On Crankshaft Bolts

NOTE: Position the piston with the indentation arrow toward the front of the
cylinder block.
12. Using the Piston Ring Compressor, install the pistons.

l Rotate the crankshaft as necessary.
Fig. 354: Installing Piston Using Piston Ring Compressor

NOTE: The old nuts and bolts are used for checking clearances. New nuts and
bolts must be used for reassembly.
13. Check the clearance of each connecting rod bearing. For additional information, refer to ENGINE
14. Rotate the crankshaft until the piston is at the bottom of its stroke.
NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole
side first. For cylinders 4, 5 and 6, remove the opposite nut first.
Fig. 355: Locating Face Distance Over End Of Bolt

15. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
16. Tap on the nut until the bolt can be removed by hand.
Fig. 356: Locating Connecting Rod Bolt

17. Repeat the previous 2 steps for the opposite bolt.

18. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting
rod.
Fig. 357: Locating Bolt Head Position

19. Install the connecting rod cap in its original position.

20. Install and tighten the connecting rod nuts finger-tight.
Fig. 358: Locating Connecting Rod Nut Tightening Position

21. Tighten the connecting rod nuts simultaneously in 2 stages:

22. Repeat the previous 4 steps for the remaining connecting rods.
23. Rotate crankshaft until the No. 1 piston is at Top Dead Center (TDC).
Vehicles equipped with a balance shaft
24. Install the balance shaft.

1. Position the balance shaft assembly.
2. Install the bolts and tighten to 27 Nm (20 lb-ft).
Fig. 359: Identifying Balance Shaft Assembly With Mounting Bolts

NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up
to 7 complete turns of the balance shaft may be required to find the
correct position.
25. Align the timing marks.

l Install a 4 mm (0.16 in) pin to hold the shaft in place.
Fig. 360: Locating Timing Marks

26. Install the balance shaft chain and crankshaft sprocket.
Fig. 361: Locating Balance Shaft Chain And Crankshaft Sprocket

27. Install the balance shaft tensioner.

1. Position the balance shaft tensioner.
2. Install the 2 bolts and tighten to 29 Nm (21 lb-ft).
3. Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 lb-in).
l Remove the pin from the tensioner.
Fig. 362: Locating Balance Shaft Chain Guide With Mounting Bolts
All vehicles
28. Position the oil pump intermediate shaft and the oil pump. Install the 2 bolts.
Fig. 363: Locating Oil Pump Intermediate Shaft, Oil Pump Pickup Tube With Bolts
29. Install the jack shaft.

30. Install the jack shaft thrust plate and bolts.


31. Install the jack shaft spacer.
Fig. 366: Locating Jackshaft Spacer

32. Install the oil pump drive and the hold down.
Fig. 367: Locating Oil Pump Drive Bolt

33. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.

34. Install the RH drive cassette bolt and spacer.

Fig. 369: Locating RH Camshaft Drive Cassette Bolt

35. Install the LH cassette and the bolt.


36. Install the crankshaft key. Position the jack shaft and crankshaft sprockets and the chain.
Fig. 371: Locating Jackshaft, Crankshaft Sprockets And Chain
37. Install the chain guide and the 2 bolts.

Fig. 372: Locating Chain Guide Bolts

38. Install the chain tensioner and the 2 bolts.

Fig. 373: Locating Chain Tensioner Bolts

39. Install the jack shaft sprocket bolt. Do not tighten the bolt at this time.

40. While holding the front jack shaft sprocket bolt secure, tighten the rear bolt.

41. Install the Rear Jack Shaft Socket on the rear of the jack shaft.
Fig. 376: Identifying Rear Jack Shaft Socket

42. Using the Rear Jack Shaft Socket to hold the jack shaft, tighten the rear jack shaft bolt an additional 90
degrees.
Fig. 377: Holding Jackshaft Using Rear Jack Shaft Socket

43. Using the Rear Jack Shaft Socket to hold the jack shaft, tighten the front sprocket bolt in 2 stages.
l Tighten an additional 90 degrees.

44. Remove the Rear Jack Shaft Sprocket and install the rear jack shaft plug.
Fig. 379: Locating Jackshaft Rear Plug

45. Position a new engine front cover gasket on the cylinder block.
NOTE: Apply thread sealant to the stud bolts and make sure that the stud bolts
are installed in their original positions.
Fig. 380: Locating Stud Bolt

46. Position the front cover and loosely install the 5 bolts and the 5 stud bolts.
47. Use the Front Cover Aligner to align the front cover and tighten the bolts and stud bolts to 19 Nm (168
lb-in).
Fig. 381: Identifying Front Cover Aligner

NOTE: Lubricate the seal lip with clean engine oil.
Fig. 382: Locating Crankshaft Front Oil Seal With Front Cover Aligner And Crankshaft Vibration
Damper Installer
48. Using the Front Cover Aligner and Crankshaft Vibration Damper Installer, install the crankshaft front oil
seal.
NOTE: Failure to back off the set screws may result in damage to the cylinder
block cradle.
Fig. 383: Locating Cylinder Block Cradle Boss Set Screw

49. Back the set screws off until they are below the cylinder block cradle boss.
Fig. 384: Locating Silicone Gasket And Sealant Applying Areas

50. Apply silicone gasket and sealant in the 6 places shown in illustration.
51. Position the lower block cradle and a new gasket.
Fig. 385: Locating Lower Block Cradle

52. Install and hand-tighten the 20 bolts and 2 nuts.

53. Install and hand-tighten the bolts.
Fig. 387: Locating Bolts

NOTE: The lower block cradle to the cylinder block alignment must be within a
maximum mismatch of 0.25 mm (0.01 in) lower block cradle underflush or
0.05 mm (0.00196 in) lower block cradle protrusion.
Fig. 388: [Locating Lower Block Cradle]

54. Using a straightedge, align the transmission face of the lower block cradle with the rear face of the
cylinder block.
55. Tighten the 20 bolts and the 2 nuts.
l Tighten the nuts to 10 Nm (89 lb-in).
l Tighten the bolts to 14 Nm (124 lb-in).

56. Install the 2 block cradle bolts.

Fig. 390: Locating Cylinder Block Cradle Torx Bolts

57. Tighten the lower block cradle inserts to 3 Nm (27 lb-in).
Fig. 391: Locating Lower Block Cradle Insert

58. Install new seals on the 2 silver bolts and loosely install them in the cylinder block cradle.
Fig. 392: Locating Silver-Colored Bolts

59. Loosely install the 6 remaining lower block cradle bolts.
Fig. 393: Locating Lower Block Cradle Bolts

60. Tighten the cylinder block cradle bolts in 2 stages.

Fig. 394: Identifying Cylinder Block Cradle Bolts Tightening Sequence

NOTE: The cylinder block cradle to the cylinder block alignment must be within a
maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush
or 0.05 mm (0.00196 in) cylinder block cradle protrusion.
61. Using a straightedge, measure the mismatch between the transmission face of the cylinder block cradle
with the rear face of the cylinder block.
l Cradles that exceed protrusion specification must be removed and the appropriate assembly steps
repeated.
l Cradles that exceed the underflush specification may be repaired by installing shims (next step).
Fig. 395: [Locating Lower Block Cradle]

62. Repair all assemblies that exceed underflush specification by installing shims on 1 or both sides of the
cylinder block cradle.
Fig. 396: Locating Cylinder Block Cradle

63. Install the oil pump screen and pickup tube and the bolt.
Fig. 397: Locating Oil Pump Screen Cover And Tube

64. Install the gasket, oil pan and the 10 bolts.

Fig. 398: Locating Oil Pan Bolts

65. Inspect and install new oil filter adapter O-ring seals if necessary.
Fig. 399: Locating Oil Filter Adapter O-ring Seals

66. Install the oil filter adapter and the bolt.

Fig. 400: Locating Oil Filter Adapter

67. Install a new oil filter.

l Tighten until the oil filter seal is flush with the adapter and the tighten an additional 270 degrees.
Fig. 401: Identifying Engine Oil Filter

68. Install a new gasket, the coolant pump and the 13 bolts.
Fig. 402: Locating Coolant Pump Bolts

69. Using the Crankshaft Vibration Damper, install the crankshaft pulley.
Fig. 403: Installing Crankshaft Pulley
NOTE: A new bolt must be used each time it is removed.
70. Using the Strap Wrench, tighten the bolt in 2 stages.

l Stage 2: Rotate an additional 85 degrees.
Fig. 404: Locating Crankshaft Pulley Bolt

71. Install the coolant pump pulley and the 4 bolts.

Fig. 405: Locating Coolant Pump Pulley Bolt

72. Position the Crankshaft Position (CKP) sensor and install the 2 bolts.
Fig. 406: Locating Crankshaft Position (CKP) Sensor Bolts

Fig. 407: Identifying Cylinder Head Gaskets

73. Position the cylinder head gaskets.
to help lift the cylinder head from the vehicle.
74. Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in illustration
in 2 stages.
Fig. 408: Identifying Cylinder Head Bolts Tightening Sequence


Fig. 409: Locating 8-mm Bolts


77. Position the RH camshaft sprocket.

Fig. 411: Identifying RH Camshaft Sprocket

NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in
the wrong direction can damage the bolt.
NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten
the bolt.
Fig. 412: Locating RH Camshaft Sprocket Bolt

78. Install and hand-tighten the RH rear camshaft sprocket bolt.

79. Install the RH cassette bolt.
Fig. 413: Locating RH Cassette Bolt

80. Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in illustration
in 2 stages.


Fig. 415: Locating 8-mm Bolts


83. Position the LH camshaft sprocket.
Fig. 417: Identifying LH Camshaft Sprocket

NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten
the bolt.

84. Install and hand-tighten the LH camshaft sprocket bolt.

85. Install the LH cassette bolt.

86. Turn the crankshaft one revolution clockwise.

Fig. 420: Installing Special Tool

NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to

correctly fit the Camshaft Holding Tool and Adapter.
Fig. 421: Installing Special Tools On Front Of Cylinder Head

88. Install the Camshaft Holding Tool and Adapter on the front of the RH cylinder head.
Fig. 422: Identifying Special Holding Tool

89. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
Fig. 423: Locating Timing Chain Tensioner

NOTE: The RH camshaft sprocket bolt is a LH threaded bolt.

2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).

92. Remove the Timing Chain Tensioner and install the RH camshaft tensioner.
Fig. 425: Locating Timing Chain Tensioner

NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts.
Camshaft sprocket must rotate freely.
Fig. 426: Identifying Special Holding Tool

93. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to

correctly fit the Camshaft Holding Tool and Adapter.
Fig. 427: Installing Special Tools On Front Of Cylinder Head

94. Install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.


2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).

97. Install a new washer and the LH camshaft tensioner.
Fig. 430: Identifying LH Camshaft Tensioner

NOTE: Install the hydraulic lash adjusters in the same positions from which they
were removed.
Fig. 431: Locating Hydraulic Lash Adjuster Nut

98. Install the hydraulic lash adjusters.

99. Rotate the crankshaft until the cam lobe is in the upward position.

NOTE: Lubricate the roller followers with clean engine oil.
Fig. 433: Locating Roller Followers

100. Using the Valve Spring Compressor, install the roller followers in their original positions.
101. Position the RH engine mount bracket and install the 4 bolts.
Fig. 434: Locating Engine Mount Bracket

102. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness. For additional information,
refer to ENGINE SYSTEM - GENERAL INFORMATION .
103. Install the 6 new RH exhaust manifold studs.
Fig. 435: Locating RH Exhaust Manifold Studs

104. Position a new RH exhaust manifold gasket and the RH exhaust manifold. Install the 6 new nuts.
Fig. 436: Identifying Exhaust Manifold

105. Position the LH engine mount bracket and install the 3 bolts.
Fig. 437: Locating Engine Mount Bracket

106. Install the 6 new LH exhaust manifold studs.

Fig. 438: Locating LH Exhaust Manifold Studs

107. Position a new LH exhaust manifold gasket and the LH exhaust manifold. Install the 6 new nuts.
Fig. 439: Locating Exhaust Manifold

NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with
clean engine oil.
108. Position the oil level indicator tube and install the bolt.

109. Clean the valve covers and cylinder head sealing surfaces with metal surface prep. Inspect and install new
gaskets as necessary.
110. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
Fig. 441: Identifying Valve Cover Torque Sequence

111. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
Fig. 442: Identifying Valve Cover Torque Sequence

112. Position the thermostat housing, hoses and coolant tube. Install the 3 bolts.
Fig. 443: Locating Thermostat Housing Hoses And Coolant Tube

113. Connect the coolant hose to the coolant pump, position the bracket and install the bolt.
Fig. 444: Identifying Coolant Hose On Coolant Pump

114. Position the Knock Sensor (KS) and install the bolt.
Fig. 445: Locating Bolt And Knock Sensor

NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of
ordinary O-rings seals can cause the fuel system to leak. Do not reuse the
O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine oil.
Fig. 446: Locating O-ring Seals

115. Install new O-ring seals on the 6 fuel injectors.

116. Position the fuel rail and injectors and install the 4 bolts.
Fig. 447: Locating Fuel Rail And Injectors

117. Position the main engine wiring harness on the engine and install the 3 bolts.
l Attach the wiring retainers.
Fig. 448: Locating Main Engine Wiring Harness

118. Connect the 3 RH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud
bolt.
Fig. 449: Locating Fuel Injector Electrical Connectors

119. Connect the 3 LH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud
bolt.
Fig. 450: Locating Fuel Injector Electrical Connectors

120. Connect the PCV valve electrical connector.
Fig. 451: Locating PCV Valve Electrical Connector

121. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
Fig. 452: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
122. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring retainers.
Fig. 453: Locating Crankshaft Position (CKP) Sensor Electrical Connector

123. Position the generator and bracket. Install the 2 bolts and the nut.
Fig. 454: Locating Generator And Bracket

124. Install the accessory drive belt tensioner and the bolt.
Fig. 455: Locating Accessory Drive Belt Tensioner And Bolt

125. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
Fig. 456: Locating Oil Pressure Sensor Electrical Connector

126. Connect the Camshaft Position (CMP) electrical connector.
Fig. 457: Locating Camshaft Position (CMP) Electrical Connector

127. Position the fuel rail supply tube brackets and install the 2 bolts.
l Tighten the bolt for the upper bracket to 6 Nm (53 lb-in).
l Tighten the bolt for the lower bracket to 10 Nm (89 lb-in).
Fig. 458: Locating Fuel Supply Tube Bracket Bolts


NOTE: Clean and inspect all sealing surfaces. Inspect and install new intake
manifold gaskets as necessary.
128. Position the intake manifold and install the 8 bolts.

Fig. 459: Identifying Intake Manifold Bolt Torque Sequence

129. Connect the KS electrical connector and attach the wiring retainer.
Fig. 460: Locating Knock Sensor (KS) Electrical Connector

Fig. 461: Locating Positive Crankcase Ventilation (PCV) Tube Fittings

131. Position the EGR tube. Connect the fitting to the LH exhaust manifold.
Fig. 462: Locating Exhaust Gas Recirculation (EGR) Tube

132. Connect the EGR tube fitting to the EGR system module.
Fig. 463: Locating EGR Tube Fitting On EGR System Module

133. Connect the EGR system module and Throttle Position (TP) sensor electrical connectors.
Fig. 464: Locating EGR System Module And Throttle Position (TP) Sensor Electrical Connectors
134. Connect the fuel rail pressure and temperature sensor electrical connector and the vacuum tube.
Fig. 465: Locating Fuel Rail Pressure And Temperature Sensor Electrical Connector And Vacuum
Tube
135. Attach the B+ terminal to the generator and install the nut.
l Attach the wiring retainer to the generator.
Fig. 466: Locating Wiring Retainer On Generator

136. Connect the generator and Throttle Body (TB) electrical connectors.
Fig. 467: Locating Generator And Throttle Body Electrical Connectors

137. Install the Engine Lifting Bracket to the RH cylinder head.
Fig. 468: Installing Special Tool To RH Cylinder Head

138. Install the Engine Lifting Bracket to the LH cylinder head.
Fig. 469: Identifying Special Tool On Engine

139. Using the Spreader Bar and Engine Lifting Brackets, remove the engine from the engine stand.
Fig. 470: Removing Engine From Engine Stand

NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. Do
not remove the speedy sleeve, it must be installed with the crankshaft rear
seal.
NOTE: Be sure the crankshaft rear sealing surface is clean and free from any rust
or corrosion. To clean the crankshaft rear seal surface area, use extra-fine
emery cloth or extra-fine 0000 steel wool with metal surface prep.
140. Lubricate the crankshaft rear oil seal with clean engine oil.
141. Install the Crankshaft Rear Oil Seal Screws and Adapter.
Fig. 471: Installing Special Tools

142. Position the crankshaft rear oil seal with speedy sleeve around the Crankshaft Rear Oil Seal Screws and
Adapter.
Fig. 472: Identifying Crankshaft Rear Oil Seal Screws

143. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear oil seal with speedy sleeve.
Fig. 473: Installing Crankshaft Rear Seal With Speedy Sleeve

144. Install the spacer plate and if equipped, the flexplate-to-crankshaft spacer.
Fig. 474: Locating Spacer Plate

NOTE: Special bolts are used for flexplate and flywheel installation. Do not use
standard bolts.
145. Install the flexplate or flywheel.

Fig. 475: Identifying Flexplate Torque Sequence

INSTALLATION
ENGINE
Special Tool(s)

303-050 (T70P-6000)
Spreader Bar
Material
Item Specification
WSS-M2C929-
A
XG-3-A A
Installation
NOTE: Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in
clamp load on the crankshaft pulley and timing sprocket, which could cause
severe engine damage.
All vehicles
1. Using the Spreader Bar and Engine Lifting Bracket, position the engine in the vehicle.
Fig. 476: Positioning Engine In Vehicle

2. Install the RH engine mount nut.

Fig. 477: Locating Engine Mount Nut

3. Install the LH engine mount nut.

Fig. 478: Locating Engine Mount Nut

4. Attach the ground cable to the RH strut tower and install the bolt.
Fig. 479: Locating Ground Cable On Strut Tower

5. Attach the battery cable harness pin-type retainer to the cowl.
Fig. 480: Locating Battery Cable Harness Pin-Type Retainer To Cowl

6. Connect the 68-pin connector to the Power Distribution Box (PDB) and tighten the bolt.
l Attach the PDB upper housing to the lower housing.
Fig. 481: Locating Power Distribution Box Upper Housing

7. Attach the B+ terminal to the PDB and install the bolt.

l Attach the pin-type retainer from the strut tower.
Fig. 482: Locating Pin-Type Retainer

8. Install the PDB cover.

9. Attach the 3 wiring harness retainers.
Fig. 483: Locating Wiring Harness Retainers

10. Connect the 16-pin electrical connector and attach the 2 wiring retainers.
Fig. 484: Locating 16-Pin Electrical Connector

11. Connect the upper and lower PCM electrical connectors.
Fig. 485: Locating Upper And Lower Powertrain Control Module (PCM) Electrical Connectors
12. Connect the fuel vapor vent tube to the intake manifold.
Fig. 486: Locating Fuel Vapor Vent Tube To Intake Manifold

13. Connect the brake booster vacuum hose to the upper intake manifold.
Fig. 487: Locating Brake Booster Vacuum Hose On Upper Intake Manifold
14. Attach the crankcase vent tube to the LH valve cover.
Fig. 488: Locating Crankcase Vent Tube

15. Position the ignition coil and spark plug wires and install the 2 bolts.
Fig. 489: Locating Ignition Coil Bracket Bolts

16. Install the 2 upper ignition coil bracket bolts.

Fig. 490: Locating Upper Ignition Coil Bracket Bolts

17. Connect the ignition coil electrical connector.
Fig. 491: Locating Ignition Coil Electrical Connector

18. Connect the radio ignition interference capacitor electrical connector.
Fig. 492: Locating Radio Ignition Interference Capacitor Electrical Connector

19. Attach the spark plug wire retainer to the intake manifold.
Fig. 493: Locating Spark Plug Wire Retainer On Intake Manifold

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound
to the inside of the spark plug wire boots before installation.
20. Connect the 6 spark plug wires to the spark plugs.

l Attach the retainers to the valve cover stud bolts and the ignition coil bracket.
Fig. 494: Connecting Spark Plug Wires

21. Install the 2 coolant tube bracket bolts.


22. Connect the 2 heater hoses to the coolant tube.
Fig. 496: Locating Heater Hoses On Coolant Tube

23. Position the Front End Accessory Drive (FEAD) bracket and A/C compressor. Install the 3 bolts and the
nut.
Fig. 497: Positioning Front Engine Accessory Drive (FEAD) Bracket

Fig. 498: Locating Power Steering Pump

25. Position the power steering pump pulley and install the 3 bolts.
l Do not tighten at this time.
Fig. 499: Locating Power Steering Pump Pulley

26. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
Fig. 500: Identifying Accessory Drive Belt Routing - 4.0L SOHC

27. Tighten the 3 power steering pulley bolts.

Fig. 501: Locating Power Steering Pump Pulley

28. Connect the fuel supply tube coupling. For additional information, refer to FUEL SYSTEM -
Fig. 502: Locating Fuel Supply Tube Coupling

29. Attach the 2 wiring retainers to the FEAD bracket.
Fig. 503: Locating Wiring Retainers On Feed Bracket

30. Connect the A/C compressor and A/C high pressure switch electrical connectors.
Fig. 504: Locating A/C Compressor And A/C High Pressure Switch Electrical Connectors
31. Connect the Power Steering Pressure (PSP) switch electrical connector.
Fig. 505: Locating Power Steering Pressure (PSP) Switch Electrical Connector
32. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt.
Fig. 506: Identifying Power Steering Supply Hose Bracket

33. Position the Power Steering Pressure (PSP) tube bracket on the A/C compressor and install the nut.
Fig. 507: Identifying Power Steering Pressure Tube Bracket On A/C Compressor
34. Connect the lower radiator hose to the coolant pump.
Fig. 508: Locating Lower Radiator Hose On Coolant Pump

35. Connect the upper radiator hose to the thermostat housing.
Fig. 509: Locating Upper Radiator Hose On Thermostat Housing

36. Position the ground strap and install the stud bolt.
Fig. 510: Positioning Ground Strap

Vehicles with manual transmission
37. Install the clutch. For additional information, refer to CLUTCH .
Vehicles with automatic transmission
38. Install the transmission. For additional information, refer to AUTOMATIC

All vehicles


40. Connect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical
connectors (1 shown).
Fig. 512: Locating Heated Oxygen Sensor (HO2S)

NOTE: Use the index marks made during the removal procedure for correct hood
alignment.
41. Position the hood and install the 4 bolts.

42. Connect the windshield washer hose and position the hood insulation.
Fig. 513: Locating Windshield Washer Hose

43. Install the 1 hood insulation pin-type retainer and attach the 2 windshield washer hose retainers.
Fig. 514: Locating Windshield Washer Hose Retainers

44. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR
46. Connect the battery ground and positive cables. For additional information, refer to BATTERY,
MOUNTING AND CABLES .
47. Fill and bleed the cooling system. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .

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2010 Ford Mustang Shelby GT500

2010 ENGINE Engine - 4.0L SOHC - Mustang

Engine - 4.0L SOHC - Mustang

martes, 9 de junio de 2020 09:58:18

Valve stem diameter - intake 6.965-6.98 mm (0.274-0.275 in)

0.008 mm (0.0003 in)

TORQUE SPECIFICATIONS CHART

TORQUE SPECIFICATIONS CHART

Bell housing-to-cylinder block cradle bolts 47 35 -

Hood hinge bolts 12 - 106

(1) Refer to the procedure.

DESCRIPTION AND OPERATION

The 4.0L SOHC engine consists of the following:

l Single overhead camshafts

Engine Code Information Label

Fig. 1: Identifying Engine Code Information Label

Engine Cylinder Identification

Fig. 2: Identifying Engine Cylinder Identification Label

Exhaust Emission Control System

l electronic Throttle Body (TB).

The fuel charging and controls system is:

l Pulse Width Modulated (PWM).

The PCV valve:

The EGR system module transducer:

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

The engine cooling system includes the following:

DIAGNOSIS AND TESTING

For basic mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .

For driveability concerns, refer to the INTRODUCTION - GASOLINE MODELS .

SPECIAL TOOLS DESCRIPTION CHART

Adapter for 303-564

Adapter for 303-577

Holding Tool, Camshaft

Holding Tool, Camshaft Sprocket

Socket, Camshaft Sprocket Nut

Tensioner, Timing Chain

Timing Tool, Crankshaft TDC

Torque Wrench Extension

NOTE: The LH and RH camshafts must be retimed when either camshaft is

NOTE: Do not rotate the engine counterclockwise. Rotating the engine

Fig. 3: Identifying Crankshaft TDC Timing Tool

5. Install the Crankshaft TDC Timing Tool.

NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.

Fig. 5: Removing/Installing Camshaft Sprocket Bolt Using Torque Wrench Extension

Fig. 6: Locating Camshaft Sprocket Holding Tool Clamp Bolts

NOTE: The camshaft timing slots are off-center.

Fig. 8: Locating RH Camshaft Tensioner

11. Install the Timing Chain Tensioner.

Fig. 9: Identifying Timing Chain Tensioner

NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.

12. Tighten the bolts.

Fig. 10: Tightening RH Camshaft Sprocket Bolt

13. Remove the Timing Chain Tensioner.

Fig. 11: Identifying Timing Chain Tensioner

NOTE: Install a new washer on the tensioner.

14. Install the RH camshaft tensioner.

Fig. 12: Locating RH Camshaft Tensioner

Fig. 13: Identifying Camshaft Sprocket Holding Tool And Adapter

16. Loosen the LH camshaft sprocket bolt.