Section 1440 (Engine - 3.0L (4V)): Assembly: Engine
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tool(s)
| Compressor, Piston Ring 303-D032 (D81L-6002-C) | |
| Dial Indicator Gauge with Holding Fixture 100-002 (TOOL_4201-C) | |
| Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) | |
| Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 | |
| Installer, Connecting Rod 303-462 (T94P-6136-AH) | |
| Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) | |
| Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) | |
| Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) | |
| Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) | |
| Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) | |
| Lifting Brackets, Engine 303-050 (T70P-6000) | |
| Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) | |
| Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455 | |
| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent |
Material
| Item | Specification |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A | ESE-M1C171-A |
| Motorcraft Metal Surface Prep ZC-31 | - |
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent | WSS-M2C930-A |
| Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
Lower Engine Block (View 1)
| Item | Part Number | Description |
|---|---|---|
| 1 | 12A227 | Ignition pulse wheel |
| 2 | 6L266 | RH timing chain tensioner |
| 3 | 6K255 | RH timing chain tensioner arm |
| 4 | 6268 | RH timing chain |
| 5 | 6M256 | RH timing chain guide |
| 6 | 6306 | Crankshaft sprocket |
| 7 | 6L266 | LH timing chain tensioner |
| 8 | 6K255 | LH timing chain tensioner arm |
| 9 | 6268 | LH timing chain |
| 10 | 6B297 | LH timing chain guide |
| 11 | 6621 | Oil pump |
| 12 | W701923 | Cup plug |
| 13 | 6B752 | Oil separator gasket |
| 14 | - | Cover |
| 15 | 8A505 | Water inlet tube |
| 16 | 6701 | Crankshaft rear oil seal |
| 17 | - | Spacer plate |
| 18 | 6375 | Flexplate |
| 19 | - | Oil pressure sender |
| 20 | W705934 | Woodruff key |
| 21 | 6622 | Oil pickup tube and screen |
| 22 | 6687 | Oil pan baffle |
| 23 | 6714 | Oil filter |
| 24 | 6675 | Oil pan |
| 25 | 3A674 | Power steering pump and pulley |
| 26 | 6B209 | Accessory drive belt tensioner |
| 27 | 6700 | Crankshaft front seal |
| 28 | 6316 | Crankshaft vibration damper |
| 29 | W701511 | Crankshaft vibration damper washer |
| 30 | W701512 | Crankshaft vibration damper bolt |
| 31 | 6B288 | Crankshaft position (CKP) sensor |
| 32 | 6C315 | Camshaft position (CMP) sensor |
| 33 | - | Accessory drive belt idler pulley |
| 34 | 6019 | Front cover |
Lower Engine Block (View 2)
| Item | Part Number | Description |
|---|---|---|
| 1 | 6150 | Piston compression upper ring (6 required) |
| 2 | 6152 | Piston compression lower ring (6 required) |
| 3 | 6159 | Piston oil control upper segment ring (6 required) |
| 4 | 6161 | Piston oil control spacer (6 required) |
| 5 | 6159 | Piston oil control lower segment ring (6 required) |
| 6 | 6140 | Piston pin retainer (12 required) |
| 7 | 6135 | Piston pin (6 required) |
| 8 | 6110 | Piston (6 required) |
| 9 | 6200 | Connecting rod (6 required) |
| 10 | 6211 | Connecting rod upper bearing (6 required) |
| 11 | 6211 | Connecting rod lower bearing (6 required) |
| 12 | 6210 | Connecting rod cap (6 required) |
| 13 | 6010 | Cylinder block |
| 14 | 6333 | Cylinder block crankshaft main bearing (4 required) |
| 15 | 6A341 | Crankshaft upper thrust bearing |
| 16 | 6303 | Crankshaft |
| 17 | 6333 | Lower cylinder block crankshaft main bearings (3 required) |
| 18 | 6337 | Lower cylinder block crankshaft main thrust bearing |
| 19 | 6F095 | Lower cylinder block |
Intake Manifolds and Valve Train
| Item | Part Number | Description |
|---|---|---|
| 1 | 6582 | RH valve cover |
| 2 | 18801 | Radio ignition interference capacitor |
| 3 | 12B637 | Engine control sensor and fuel charging wiring harness |
| 4 | - | Positive crankcase ventilation (PCV) valve |
| 5 | - | PCV tube |
| 6 | 9424 | Upper intake manifold |
| 7 | 9J472 | Exhaust gas recirculation (EGR) vacuum regulator |
| 8 | 9D460 | EGR valve |
| 9 | 9E498 | Vacuum harness |
| 10 | 9F715 | Idle air control (IAC) valve |
| 11 | 9E926 | Throttle body |
| 12 | 4682 | Fuel rail pressure and temperature sensor |
| 13 | 9F792 | Fuel rail |
| 14 | 9J477 | Lower intake manifold |
| 15 | 12A366 | Coil-on-plug (6 req'd) |
| 16 | 6A505 | LH valve cover (Early build) |
| 17 | 6A359 | Coolant pump drive pulley (Early build) |
| 18 | 6B293 | Rear seal retainer (Early build) |
| 19 | 6B280 | Camshaft bearing cap (Early build) |
| 20 | 6B280 | Camshaft thrust bearing cap (Early build) |
| 21 | 6A267 | LH intake camshaft (Early build) |
| 22 | 8548 | Coolant bypass tube |
| 23 | 6A269 | LH exhaust camshaft (Early build) |
| 24 | 12405 | Spark plug |
| 25 | 6C501 | Hydraulic lash adjuster |
| 26 | 6514 | Valve spring retainer |
| 27 | 6529 | Camshaft follower |
| 28 | 6518 | Valve spring retainer key |
| 29 | 6513 | Valve spring |
| 30 | 6A517 | Valve stem seal |
| 31 | 8501 | Coolant pump (Early build) |
| 32 | 8K543 | Coolant pump belt (Early build) |
| 33 | - | LH engine lifting eye |
| 34 | - | Oil level indicator |
| 35 | 6754 | Oil level indicator tube |
| 36 | 6083 | LH cylinder head gasket |
| 37 | 6507 | Intake valve |
| 38 | 6505 | Exhaust valve |
| 39 | 6049 | LH cylinder head (Early build) |
| 40 | 6051 | RH cylinder head gasket |
| 41 | 6050 | RH cylinder head |
| 42 | 6A266 | RH intake camshaft |
| 43 | 6A268 | RH exhaust camshaft |
| 44 | 6B280 | Camshaft bearing cap |
| 45 | 6A258 | Camshaft journal cap |
Camshaft and Coolant Pump (Late Build)
| Item | Part Number | Description |
|---|---|---|
| 1 | 6A505 | LH valve cover (Late build) |
| 2 | 6B280 | Camshaft thrust bearing cap (Late build) |
| 3 | 6B280 | Camshaft bearing cap (Late build) |
| 4 | 6A267 | LH intake camshaft (Late build) |
| 5 | 6A269 | LH exhaust camshaft (Late build) |
| 6 | 6A359 | Coolant pump drive pulley (Late build) |
| 7 | 6B293 | Rear seal retainer (Late build) |
| 8 | 8K543 | Coolant pump drive belt (Late build) |
| 9 | 8501 | Coolant pump (Late build) |
| 10 | 6049 | LH cylinder head (Late build) |
NOTE:
During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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.
NOTE:
If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.
NOTE:
Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION
.
NOTE:
Early build vehicles are equipped with the coolant pump drive pulley on the LH intake camshaft, late build vehicles are equipped with the coolant pump drive pulley on the LH exhaust camshaft.
All vehicles
- 1.
Select the crankshaft main bearings for each crankshaft journal.- 1.
Read the code on the crankshaft flange.
- 2.
Read the code on the cylinder block rear face.- The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
- The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
- 1.
NOTE:
This procedure is for selecting bearings using a new crankshaft.
- 2.
Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.- For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
- 3.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
NOTE:
Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
- 4.
Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
- 9.
Apply gasket and sealant to the cylinder block as shown below.
NOTE:
Clean and degrease both surfaces using metal surface prep before applying sealant.
NOTE:
The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.
- 10.
Position the lower cylinder block and install the new bolts and new studs.- Tighten the bolts and studs in the sequence shown below in 4 stages.
- Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
- Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
- Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
NOTE:
Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in) /M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.
- 11.
Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
- 12.
Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
- 16.
Using the chart, select the correct piston grade size for the cylinder bores.- Measure the cylinder block bore diameter.
- Mark the outside of the block with the appropriate number(s) to identify bore grade size.
- Choose the correct piston grade size for the cylinder bore.
- 17.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
NOTE:
After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
NOTE:
Make sure the piston arrow on top is facing toward the front of the engine.
NOTE:
Make sure the piston rings are positioned to specifications for installation. For additional information, refer to Disassembly and Assembly of Subassemblies - Piston.
NOTE:
Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE:
Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
- 18.
Install the connecting rod caps and the new bolts.- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
NOTE:
The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- 20.
Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown below in 6 stages.- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten to 90 Nm (66 lb-ft).
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten 90 degrees.
- Stage 6: Tighten 90 degrees.
NOTE:
LH shown, RH similar.
- 21.
Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
- 23.
Install the LH and RH camshaft roller followers.
NOTE:
RH shown, LH similar.
NOTE:
The camshaft roller followers must be installed in their original positions.
Early build vehicles
- 26.
Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.- Loosely install the bolts.
NOTE:
Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.
NOTE:
The camshaft caps must be installed in their original positions or damage to the engine may occur.
- 27.
Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.- Loosely install the bolts.
Late build vehicles
- 29.
Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.- Loosely install the bolts.
NOTE:
Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.
NOTE:
The camshaft caps must be installed in their original positions or damage to the engine may occur.
- 30.
Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.- Loosely install the bolts.
All vehicles
- 32.
Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps.- Loosely install the bolts.
NOTE:
Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.
NOTE:
The camshaft caps must be installed in their original positions or damage to the engine may occur.
- 33.
Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.1
- Loosely install the bolts.
- 35.
Install the camshaft oil seal retainer and the bolts.- Tighten to 10 Nm (89 lb-in).
NOTE:
Early build shown, late build similar.
NOTE:
Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
- 36.
Using the special tools, install a new camshaft oil seal.
NOTE:
Early build shown, late build similar.
NOTE:
Apply clean engine oil to the seal lip and seal bore before installing the seal.
- 37.
Install the special tool in the camshaft as shown in the illustration.- Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
NOTE:
Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
- 38.
Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.- Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
NOTE:
Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).
NOTE:
Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE:
On early build engines, the OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. On late build engines, the OEM pulley is pressed on flush to the end of the camshaft. Service pulleys on all engines are pressed on flush to the end of the camshaft.
- 40.
Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
NOTE:
Failure to verify correct timing drive component alignment will result in severe engine damage.
- 42.
Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE:
LH shown, RH similar.
- 43.
Slowly compress the timing chain tensioner.
NOTE:
During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
- 45.
If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.- 1.
Mark any link to use as the crankshaft timing mark.
- 2.
Starting with the crankshaft timing mark, count 29 links and mark the link.
- 3.
Continue counting to link 42 and mark the link.
- 1.
- 46.
Position the LH timing chain and guide and install the bolts.- Tighten to 25 Nm (18 lb-ft).
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
- 47.
Install the LH timing chain tensioner arm and the LH timing chain tensioner.- 1.
Install the tensioner arm.
- 2.
Position the tensioner.
- 3.
Install the bolts.
- Tighten to 25 Nm (18 lb-ft).
- 1.
- 48.
Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
- 50.
Install the RH timing chain and chain guide and install the bolts.- Tighten to 25 Nm (18 lb-ft).
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
- 51.
Install the RH timing chain tensioner and tensioner arm.- 1.
Install the tensioner arm.
- 2.
Position the tensioner.
- 3.
Install the bolts.
- Tighten to 25 Nm (18 lb-ft).
- 1.
- 54.
Verify the timing with the following steps.- 1.
There should be 12 chain links between the camshaft timing marks.
- 2.
There should be 27 chain links between the camshaft and the crankshaft timing marks.
- 3.
There should be 30 chain links between the camshaft and the crankshaft timing marks.
- 1.
NOTE:
Failure to verify correct timing drive component alignment will result in severe engine damage.
- 56.
Install the ignition pulse wheel.
NOTE:
This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).
- 58.
Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
NOTE:
The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
NOTE:
Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
- 59.
Position the front cover and install the bolts and stud bolts.- Tighten in the sequence shown below to 25 Nm (18 lb-ft).
NOTE:
Fasteners 1, 8, 13 and 16 are stud bolts.
- 62.
Using the special tools, install the crankshaft front oil seal.
NOTE:
Apply clean engine oil to the seal lip and seal bore before installing the seal.
- 63.
Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
NOTE:
The crankshaft damper must be installed and the bolt tightened within four minutes of sealant application.
NOTE:
Sealing surfaces must be free of dirt and oil.
NOTE:
Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
- 64.
Using the special tool, install the crankshaft vibration damper.
NOTE:
Lubricate the outside diameter sealing surface with clean engine oil.
- 65.
Install the crankshaft vibration damper washer and tighten the bolt in 4 stages.- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn (360 degrees).
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten to 90 Nm (66 lb-ft).
- 68.
Position the oil pan baffle. Install the nuts and tighten in 2 stages.- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten 45 degrees.
- 69.
Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
- 70.
Install the oil pump screen and pickup tube.- 1.
Position the oil pump screen and pickup tube.
- 2.
Install the bolts.
- 3.
Install the nut and tighten in 2 stages.- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten 45 degrees.
- 1.
- 72.
Position the oil level indicator and tube and install the stud bolt.- Tighten to 10 Nm (89 lb-in).
- 78.
Lubricate the O-ring seal and install the oil filter.- Tighten the oil filter 3/4 of a turn after the filter gasket makes contact with the oil filter adapter.
4x2 vehicles
- 81.
Install a new gasket and the RH exhaust manifold and new nuts.- Tighten in the sequence shown below to 20 Nm (15 lb-ft).
All vehicles
- 83.
Install a new gasket and the LH exhaust manifold and new nuts.- Tighten in the sequence shown below to 20 Nm (15 lb-ft).
- 84.
Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
NOTE:
Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
- 85.
Install the LH and RH spark plugs.- Tighten to 15 Nm (11 lb-ft).
NOTE:
Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
- 86.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
NOTE:
Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
NOTE:
The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE:
LH shown, RH similar.
Early build vehicles
- 87.
Position the LH valve cover and install the bolts and stud bolts.- Tighten in the sequence shown below to 10 Nm (89 lb-in).
NOTE:
Install a new valve cover gasket.
Late build vehicles
- 88.
Position the LH valve cover and install the bolts and stud bolts.- Tighten in the sequence shown below to 10 Nm (89 lb-in).
NOTE:
Install a new valve cover gasket.
All vehicles
- 90.
Position the RH valve cover and install the bolts and stud bolts.- Tighten in the sequence shown below to 10 Nm (89 lb-in).
NOTE:
Install a new valve cover gasket.
- 92.
Install the 6 coil-on-plugs and the bolts.- Tighten to 6 Nm (53 lb-in).
NOTE:
LH shown, RH similar.
- 94.
Install the lower intake manifold and the bolts.- Tighten in the sequence shown below to 10 Nm (89 lb-in).
NOTE:
Install new gaskets.
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.
- 97.
Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.
- 98.
Connect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and attach the wiring retainers.
- 103.
Install the upper intake manifold and the bolts.- Tighten in the sequence shown below to 10 Nm (89 lb-in).
NOTE:
Install new gaskets.
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.
- 105.
Connect the vacuum tube fittings to the EGR valve, EGR vacuum regulator and the intake manifold.
- 107.
Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors and attach the wiring retainer.
- 110.
Connect the exhaust gas recirculation (EGR) vacuum regulator electrical connector. Attach the wiring harness retainer and install the nut.- Tighten to 10 Nm (89 lb-in).
- 111.
Position the heated oxygen sensor (HO2S) electrical connector bracket. Install the nut and attach the wiring retainer.- Tighten to 10 Nm (89 lb-in).
- 114.
Using the special tools, install the crankshaft rear oil seal.
NOTE:
Lubricate the seal lips and seal bore with clean engine oil before installing.