Item Specification Fill Capacity: 2010 Ranger Workshop Manual

2010 Ranger Workshop Manual
SECTION 303-01A: Engine - 2.3L 2010 Ranger Workshop Manual

SPECIFICATIONS Procedure revision date: 09/01/2009
Material
Item Specification Fill

Capacity
High Temperature 4x4 Front WSS-M1C267-A1 -
Axle and Wheel Bearing Grease
XG-11
Motorcraft® Metal Surface Prep - -
ZC-31-A
Motorcraft® Premium Gold WSS-M97B51-A1 -
Engine Coolant
VC-7-B (US); CVC-7-B
(Canada)
Motorcraft® SAE 5W-20 WSS-M2C945-A 3.8L (4 qt)
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Premium Synthetic Blend Motor with filter
Oil (US); Motorcraft® SAE change
5W-20 Super Premium Motor
Oil (Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease ESB-M1C93-B -
XG-4 and/or XL-5
Silicone Brake Caliper Grease ESE-M1C171-A -
and Dielectric Compound
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4 -
TA-30
Motorcraft® Silicone Gasket - -
Remover
ZC-30
Thread Sealant with PTFE WSK-M2G350-A2 -
TA-24
General Specifications
Item Specification
Displacement 2.3L
No. of cylinders 4
Bore/stroke 87.5/94.0
Firing order 1-3-4-2
Oil pressure (hot @ 2,000 rpm) 200-268 kPa
(29-39 psi)
133 kg (293 lb)
Powertrain/Drivetrain Mount Neutralizing 831

Engine weight (without accessory

drive components)
Cylinder Block
Cylinder bore diameter 87.5-87.53 mm
(3.444-3.445 in)
Out of round 0.008 mm
(0.0003 in)
Main bearing bore diameter 57.020-57.038 mm
(2.244-2.245 in)
Head face flatness 0.1 mm (0.004 in) maximum overall, 0.05 mm (0.002 in) in any 200
mm x 200 mm (7.87 in x 7.87 in) area
Piston
Diameter (1) 87.5-87.51 mm
(3.444-3.445 in)
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Diameter (2) 87.51-87.52 mm
(3.4452-3.4456 in)
Diameter (3) 87.52-87.53 mm
(3.444-3.446 in)
Piston to bore clearance 0.025-0.045 mm
(0.0009-0.0017 in)
Ring groove width - top 1.203-1.205 mm
(0.0473-0.0474 in)
Ring groove width - 2nd 1.17-1.19 mm
(0.0.460-0.0468 in)
Ring groove width - oil 2.501-2.503 mm
(0.0984-0.0985 in)
Piston skirt coating thickness 0.008-0.020 mm
(0.0003-0.0007 in)
Piston Pin
Diameter 20.995-21.0 mm
(0.8266-0.8268 in)
Length 59.6-60.4 mm
(2.346-2.377 in)
Piston to pin clearance 0.008-0.016 mm
(0.0003-0.0006 in)
Pin to rod clearance Press fit

Cylinder Head
Exhaust valve lift (in @ zero lash) 7.4 mm (0.2913 in)
Intake valve lift (in @ zero lash) 7.9 mm (0.3110 in)
Valve guide diameter 5.509-5.539 mm
(0.216-0.218 in)
Valve seat width - intake/exhaust 0.99-1.84 mm
(0.038-0.072 in)
Valve seat angle 45 degrees
Valve seat runout 0.075 mm (0.0029 in)
Valve lash adjustor bore diameter 31.00-31.03 mm
(1.220-1.221 in)
Cam bore diameter 25.015-25.040 mm
(0.984-0.985 in)
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Cylinder head flatness 0.08 mm (0.003 in) maximum overall, 0.05 mm (0.002 in) maximum in
any 150 mm x 150 mm (6 in x 6 in) area
Valve
Valve head diameter - intake 34.85-35.15 mm
(1.372-1.383 in)
Valve head diameter - exhaust 29.85-30.15 mm
(1.175-1.187 in)
Valve stem diameter - intake 5.470-5.485 mm
(0.2153-0.2159 in)
Valve stem diameter - exhaust 5.465-5.480 mm
(0.2151-0.2157 in)
Valve stem to guide clearance - 0.0027 mm (0.0009 in)
intake
Valve stem to guide clearance - 0.0029 mm (0.0011 in)
exhaust
Valve face runout 0.05 mm (0.001 in)
Valve face angle 45 degrees
Valve Spring - Compression Pressure
Intake and exhaust (installed) 38.667 lb
Intake (valve open) 8.9 mm (0.35 97.032 lb
in) of lift
Exhaust (valve open) 7.4 mm of lift 93.338 lb
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
Main bearing journal diameter 51.980-52.000 mm

(2.046-2.047 in)
Production repair 51.730-51.750 mm
(2.036-2.037 in)
Main bearing clearance 0.017-0.047 mm
(0.0007-0.0018 in)
Connecting rod journal diameter 49.980-50.000 mm
(1.967-1.968 in)
Production repair 49.730-49.750 mm
(1.957-1.958 in)
End play 0.22-0.43 mm
(0.008-0.016 in)
Rings
Width - top 1.17-1.185 mm
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(0.0460-0.0466 in)
Width - 2nd 1.197-1.199 mm
(0.0471-0.0472 in)
Width - oil 2.38-2.45 mm
(0.093-0.096 in)
Ring gap (in bore) - top 0.16-0.31 mm
(0.006-0.012 in)
Ring gap (in bore) - 2nd 0.33-0.48 mm
(0.012-0.018 in)
Ring gap (in bore) - oil 0.2-0.7 mm
(0.007-0.027 in)
Valve Tappet
Diameter 30.97-30.98 mm
(1.2192-1.2196 in)
Tappet to valve clearance - intake 0.22- 0.28 mm (0.008-0.011 in)
Tappet to valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in)
Tappet to bore clearance 0.02-0.06 mm
(0.0007-0.0023 in)
Camshaft
Lobe lift - intake 8.24999 mm (0.324 in)
Lobe lift - exhaust 7.80007 mm (0.307 in)
Runout (1) a 0.03 mm (0.001 in)
Thrust clearance

0.09-0.24 mm
(0.003-0.009 in)
Journal diameter 24.96-24.98 mm
(0.982-0.983 in)
Journal to bore clearance 0.035-0.080 mm
(0.001-0.003 in)
Connecting Rod
Bearing clearance 0.027-0.052 mm
(0.001-0.002 in)
Bearing thickness 1.496-1.520 mm
(0.058-0.059 in)
Crank bore diameter 53.025-53.045 mm
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(2.087-2.088 in)
Pin bore diameter 20.965-20.985 mm
(0.825-0.826 in)
Length (center to center) 154.8 mm (6.094 in)
Side clearance 1.95-3.05 mm
(0.076-0.120 in)
Axial clearance 0.14-0.36 mm
(0.005-0.014 in)
a No. 3 Journal - Supported by No. 1 and No. 5 Journals.
All dimensions are in mm unless noted.
Torque Specifications
Description Nm lb-ft lb-in

A/C compressor bolts 25 18 -
A/C manifold tube bolt 20 - 177
Accessory drive belt tensioner bolt 50 37 -
Battery cable nuts 12 - 106
Camshaft bearing caps a - - -
Camshaft Position (CMP) sensor bolts 7 - 62
Camshaft sprocket bolts 72 53 -
Clutch pressure plate bolts 32 24 -
Connecting rod bearing cap bolts a - - -

Coolant outlet (front) pipe bolts 25 18 -

Coolant outlet pipe bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 - 177
Coolant thermostat bolts 10 - 89
Coolant tube nuts 20 - 177
Crankcase vent oil separator bolts 10 - 89
Crankshaft oil seal retainer bolts a - - -
Crankshaft Position (CKP) sensor bolts 7 - 62
Crankshaft pulley bolt a - - -
Cylinder block coolant drain plug 55 41 -
Cylinder head bolts a - - -
Cylinder Head Temperature (CHT) sensor 12 - 106
EGR outlet tube-to-cylinder head fitting 55 41 -
EGR outlet tube-to-intake manifold flange bolts 18 - 159
EGR tube support bracket bolt 10 - 89
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EGR valve bolts 20 - 177
Engine front cover bolts a - - -
Engine ground cable-to-cylinder head stud bolt 10 - 89
Engine lifting eye bolts 45 33 -
Engine Oil Pressure (EOP) 15 - 133
Engine support insulator-to-crossmember nuts 103 76 -
Engine support insulator-to-engine bracket nuts 102 75 -
Engine-to-transmission bolts 48 35 -
Engine wire harness connector bracket bolt 10 - 89
Exhaust manifold-to-cylinder head nuts 54 40 -
Exhaust manifold-to-cylinder head studs 17 - 150
Exhaust manifold-to-exhaust downpipe flange nuts 40 30 -
Flywheel or flexplate bolt a - - -
Fuel rail bolts 25 18 -
Generator battery cable nut 12 - 106
Generator/A/C compressor support bracket bolts a - - -
Ground strap bolt 10 - 89
Ignition coil bolts 6 - 53
Intake manifold bolts 18 - 159
Knock Sensor (KS) bolt 20 - 177
Main bearing beam bolts a - - -
Motor mount bolts 49 36 -
Oil drain plug 28 21 -
Oil filter adapter bolts 25 18 -
Oil level indicator tube bolt 10 - 89
Oil pan bolts a - - -
Oil pump assembly bolts a - - -
Oil pump chain tensioner bolts 10 - 89

Oil pump pickup tube and screen bolts 10 - 89

Oil pump sprocket bolt 25 18 -
Oil squirters 4 - 35
PCM harness ground cable stud bolt 10 - 89
PCM harness retainer nut 4 - 35
Power Steering Pressure (PSP) tube nut 20 - 177
Power steering pump bolts 25 18 -
Solenoid control wire and nut 6 - 53
Spark plugs 12 - 106
Starter motor bolts 25 18 -
Starter wiring harness bolt 24 18 -
Throttle Body (TB) shield bolts 8 - 71
Timing chain guide bolts 10 - 89
Timing chain tensioner bolts 10 - 89
Timing peg plug 20 - 177
Torque converter-to-flywheel nuts 35 26 -
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Transmission cooling tubes bracket bolt 28 21 -
Transmission dust shield bolts 10 - 89
Transmission-to-cylinder block bolts 48 35 -
Transmission-to-oil pan bolts 48 35 -
Transmission bracket-to-transmission bolts 90 66 -
Valve cover bolts a - - -
Wiring harness bracket-to-transmission nut 10 - 89
a Refer to the procedure in this section.


DESCRIPTION AND OPERATION Procedure revision date: 09/01/2009
Engine
The 2.3L (140 CID) 4-cylinder engine has the following features:
• Dual overhead camshaft

• Four valves per cylinder
• Sequential Multi-Port Fuel Injection (SFI)
• Aluminum cylinder head
• Aluminum cylinder block
• Electronic ignition system with 2 coil packs
The 2.3L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless
ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder
assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to
provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to
open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain.
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The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston
with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven
by the same sprocket that drives the timing chain.
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.
Engine Code Information Label
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
1 Engine part number
2 Dearborn Engine and Fuel Tank Plant
3 Catch code (indicates transmission type and emission level)
4 Engine build date (DDMMYY)
5 Engine displacement
6 Plant code
7 Block finish date (DDMMYY)
8 Block finish time (HHMMSS)
Engine 838
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered
in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel
injectors:
• are mounted in the cylinder head.

• meter fuel to the air intake stream in accordance with engine demand.
• are positioned so their tips direct fuel just ahead of the engine intake valves.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake
manifold.
Lubrication System
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The engine lubrication system operates as follows:
• Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
• Oil is pumped through the oil filter on the left front side of the cylinder block.
• Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder
head.
• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate
the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting
rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire
connecting rod, piston and piston ring assembly.
Engine Cylinder Identification
Exhaust Emission Control System 839

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Engine Cylinder Identification 840


DIAGNOSIS AND TESTING Procedure revision date: 09/01/2009
Engine
For basic engine mechanical concerns, refer to Section 303-00 . For drivability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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Engine 841

GENERAL PROCEDURES Procedure revision date: 09/01/2009
Valve Clearance Check
Special Tool(s)
Feeler Gauge Set

303-D027 (D81L-4201-A) or equivalent
1. Remove the valve cover. For additional information, refer to Valve Cover in this section.
2. NOTICE: Turn the engine clockwise only and use the crankshaft bolt only or the engine may be
damaged.
NOTE: Measure the clearance of each valve at base circle with the lobe pointed away from the
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tappet, before removing the camshafts. Failure to measure all clearances prior to removing the
camshafts will necessitate repeated removal and installation and wasted labor time.
Using the Feeler Gauge Set, measure the clearance of each valve and record the location.
3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example,
a tappet with the number 0.650 has the thickness of 3.650 mm.
NOTE: The nominal desired mid-range clearance is:
• Intake: 0.25 mm (0.0095 in)

• Exhaust: 0.30 mm (0.0115 in)
Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness -
most desirable thickness.
NOTE: The acceptable clearances after being fully installed are:
• Intake: 0.22-0.28 mm (0.008-0.011 in)

• Exhaust: 0.27-0.33 mm (0.010-0.013 in)
Select the closest tappet size available and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in those locations. For
additional information, refer to Valve Tappets in this section.
Valve Clearance Check 842

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Valve Clearance Check 843


IN-VEHICLE REPAIR Procedure revision date: 09/01/2009
Intake Manifold
Material
Item Specification
Motorcraft® Metal Surface Prep -
ZC-31-A
Motorcraft® Silicone Gasket Remover -
ZC-30
Intake Manifold - Cables and LH Connections
Part
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Item Number Description
1 9A825 Speed control cable
2 N802768 Speed control cable position retainer clip
3 9A758 Accelerator control cable
4 W500222 EGR tube bolts (2 required)
5 9J280 Fuel supply tube
6 - Knock Sensor (KS) electrical connector (part of
14A290)
7 9Y476 Evaporative Emission (EVAP) vent tube quick connect
coupling
Intake Manifold 844

Intake Manifold - RH Connections
Part
8 - Manifold Absolute Pressure (MAP) sensor electrical
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connector (part of 12B637)
9 - Idle Air Control (IAC) valve electrical connector (part of
12B637)
10 9G297 Vacuum tube quick connect coupling
11 - Throttle Position (TP) sensor electrical connector (part
of 12B637)
Intake Manifold - Rear Connections
Item Part Number Description

12 381298 Brake booster vacuum hose
13 8C633 Coolant hose
14 9Y439 Coolant hose
15 6758 Crankcase breather hose
16 W500211 EGR tube support bracket bolt
17 9E498 Vacuum hose
Intake Manifold - RH Connections 845

Intake Manifold - Wiring Harness Retainers
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Part
18 13A506 Wiring harness retainer (part of 12B637)
20 - Knock Sensor (KS) electrical connector retainer (part of
12A699)
Intake Manifold
Intake Manifold - Wiring Harness Retainers 846

22 W500311 Intake manifold bolt (5 required)

23 9424 Intake manifold
24 9441 Intake manifold gasket (4 required)
Removal
1. Drain the engine cooling system. For additional information, refer to Section 303-03 .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
3. Remove the 2 bolts and the Throttle Body (TB) shield.
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4. Disconnect the acceleration control cable from the intake manifold and the TB .
5. If equipped, disconnect the speed control cable from the intake manifold and the TB .
6. Disconnect the Throttle Position (TP) sensor electrical connector.
7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
8. Disconnect the Idle Air Control (IAC) valve electrical connector.
9. Disconnect the vapor purge tube quick connect coupling. For additional information, refer to Section
310-00 .
10. Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2
coolant hoses.
11. Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.
12. Disconnect the pin-type retainer from the rear of the intake manifold.
13. Remove the EGR tube support bracket bolt.
14. Remove the 2 bolts from the EGR tube flange.
15. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the
Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to
Section 310-00 .
16. Disconnect the Knock Sensor (KS) electrical connector and disconnect the connector retainer from
the intake manifold.
17. Remove the wiring harness pushpin from the bottom of the intake manifold.
18. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section
310-00 .
Intake Manifold 847

19. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges which make leak
paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove the 5 bolts and the intake manifold.
• Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface
prep. Observe all warnings and cautions and follow all application directions contained on the
packaging of the silicone gasket remover and metal surface prep.
20. Remove and discard the 4 intake manifold gaskets.
Installation
1. NOTICE: 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.
Install 4 new intake manifold gaskets.
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2. Position the intake manifold and install the 5 bolts.
• Tighten to 18 Nm (159 lb-in).
3. Connect the wiring pushpin to the bottom of the intake manifold.
4. Connect the KS connector retainer to the intake manifold and connect the electrical connector.
5. Attach the electrical connectors and the fuel supply tube to the bracket and connect the EVAP tube
quick connect coupling. For additional information, refer to Section 310-00 .
6. Install the 2 EGR flange mounting bolts.

7. Install the EGR tube support bracket bolt.

8. Position the engine wiring harness and connect the 2 pin-type retainers.
9. Connect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2
coolant hoses.
10. Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling. For
additional information, refer to Section 310-00 .
11. Connect the MAP sensor electrical connector.
12. Connect the TP sensor electrical connector.
13. Connect the acceleration control cable to the intake manifold and the TB .
14. If equipped, connect the speed control cable to the intake manifold and the TB .
15. Position the TB shield and install the 2 bolts.
Intake Manifold 848

16. Install the ACL outlet tube. For additional information, refer to Section 303-12 .
17. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
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Intake Manifold 849


Valve Cover
Material
Item Specification
ZC-31-A
Motorcraft® SAE 5W-20 Premium WSS-M2C945-A
Synthetic Blend Motor Oil (US);
Motorcraft® SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US);
Motorcraft® Silicone Gasket -
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Remover
ZC-30
Valve Cover - Ignition Coil and Wires

1 - Ignition coil electrical connector (part of 12B637)
2 W505575 Ignition coil bolt (4 required)
3 12029 Ignition coil
4 - Spark plug wire (4 required)
Valve Cover 850

Valve Cover - Connections
Part
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5 6758 Crankcase breather tube
6 - Cylinder Head Temperature (CHT) sensor cover (part of
12B637)
7 - CHT sensor electrical connector (part of 12B637)
8 - Camshaft Position (CMP) sensor electrical connector
(part of 12B637)
9 W701219 CMP sensor bolt
10 12K073 CMP sensor
11 - CMP sensor O-ring seal
Valve Cover
Valve Cover - Connections 851

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12 14A099 Wiring harness shield/support bracket
13 6C295 Valve cover bolt (short shoulder) (6 required)
14 18801 Radio ignition interference capacitor
15 - Valve cover stud bolt (4 required)
16 - Valve cover bolt (medium shoulder) (4 required)
17 6K272 Valve cover
18 6K620 Valve cover seals (4 required)
Removal
1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
2. Remove the intake manifold assembly. For additional information, refer to Intake Manifold in this
section.
3. Position aside the Cylinder Head Temperature (CHT) sensor cover.
4. Disconnect the CHT sensor electrical connector.
5. Disconnect the engine wiring harness support bracket retainers from the valve cover studs.
6. Disconnect the spark plug wires from the spark plugs. For additional information, refer to Section
303-07A .
7. Disconnect the ignition coil electrical connector.
8. Remove the 4 bolts and the ignition coil and spark plug wires as an assembly.
9. Disconnect the Camshaft Position (CMP) sensor electrical connector.
10. Remove the bolt and the CMP sensor.
Valve Cover 852

11. Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to
Section 310-00 .
12. Remove the 10 bolts, the 4 stud bolts and the valve cover.
paths.
Clean and inspect the cylinder head sealing surfaces with metal surface prep and silicone gasket
remover. Observe all warnings and cautions and follow all application directions contained on the
packaging of the silicone gasket remover and metal surface prep.
14. Remove and discard the 4 valve cover gaskets.
Installation
1. Install 4 new valve cover gaskets.
2. Position the valve cover and install the 10 bolts and 4 stud bolts in the sequence shown.
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3. Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to
Section 310-00 .
4. NOTE: Apply clean engine oil to the O-ring seal prior to installation.
Install the CMP sensor and the bolt.
5. Connect the CMP sensor electrical connector.
6. Position the ignition coil and install the 4 bolts.

7. Connect the ignition coil electrical connector.
8. Connect the spark plug wires to the spark plugs. For additional information, refer to Section 303-07A
.
9. Install the engine wiring harness support bracket retainers onto the valve cover studs.
10. Connect the CHT sensor electrical connector.
11. Position back the CHT sensor boot.
Valve Cover 853

12. Install the intake manifold. For additional information, refer to Intake Manifold in this section.
13. Connect the battery ground cable. For additional information, refer to Section 414-01 .
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Valve Cover 854


Crankshaft Pulley
Special Tool(s)
Alignment Plate, Camshaft

303-465 (T94P-6256-CH)
Holding Tool, Crankshaft Damper

303-1416
Timing Peg, Crankshaft

303-507
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General Equipment
6 mm x 18 mm bolt
Material
Item Specification
XO-5W20-QSP (US);

1 6K340 Crankshaft pulley bolt
2 - Crankshaft pulley bolt washer
3 6316 Crankshaft pulley
4 6378 Diamond washer
Crankshaft Pulley 855

Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as
instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction,
using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket
is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools,
otherwise severe engine damage can occur.
NOTICE: 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
2. Remove the fan and shroud. For additional information, refer to Section 303-03 .
3. Remove the accessory drive belt. For additional information, refer to Section 303-05 .
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4. Remove the valve cover. For additional information, refer to Valve Cover in this section.
5. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage
to the engine. Turn the crankshaft in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top
Dead Center (TDC).
• The hole in the crankshaft pulley should be in the 6 o'clock position.
6. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to
prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.

7. Remove the timing peg plug.
8. NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC
. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must
remain at the TDC position during the crankshaft pulley removal and installation.
Install the Crankshaft Timing Peg.
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9. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal
of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be
held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using
an air impact wrench (1/2-in drive minimum).
NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley.
The diamond washer must be replaced; remove and discard the diamond washer. If the
diamond washer is not installed, engine damage may occur.
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
• Remove and discard the crankshaft pulley bolt and washer.

• Remove the crankshaft pulley.
• Remove the diamond washer and discard.
Installation

1. Install a new diamond washer.
2. NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the crankshaft front seal area before installing.
Install the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
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Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during
installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft
pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be
installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in
drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
• Stage 1: Tighten to 100 Nm (74 lb-ft).

• Stage 2: Rotate an additional 90 degrees.
5. Remove the 6 mm x 18 mm bolt.

6. Remove the Crankshaft Timing Peg.
7. Remove the Camshaft Alignment Plate.
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8. NOTE: Only turn the crankshaft in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft Timing Peg.
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.

11. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
• If it is not possible to install the bolt, the engine valve timing must be corrected by repeating
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this procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts.
• If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be
corrected by repeating this procedure.

16. Install the timing peg plug.

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17. Install the valve cover. For additional information, refer to Valve Cover in this section.
18. Install the accessory drive belt. For additional information, refer to Section 303-05 .
19. Install the fan and shroud. For additional information, refer to Section 303-03 .


Crankshaft Front Seal
Special Tool(s)
Installer, Camshaft Front Oil Seal

303-096 (T74P-6150-A)
Remover, Seal
303-409 (T92C-6700-CH)
Material
Item Specification
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XO-5W20-QSP (US);

1 6700 Crankshaft front seal
Removal
1. NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special
tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft
timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and
the pulley are fitted together by friction, using diamond washers between the flange faces on
each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is
loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the
crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine
damage can occur.
Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
2. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal, or oil leakage may occur.
Using the Seal Remover, remove the crankshaft front seal.
Crankshaft Front Seal 862

Installation
1. NOTE: Lubricate the new crankshaft front seal with clean engine oil prior to installation.
Using the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.
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2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
Crankshaft Front Seal 863


Engine Front Cover
Special Tool(s)
Aligner, Crankshaft Sensor

303-1417
General Equipment
6 mm x 18 mm bolt
Material
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Item Specification
ZC-31-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Remover
ZC-30
Engine Front Cover - Accessories
Engine Front Cover 864

Part
1 - Accessory drive belt tensioner bolt
2 - Accessory drive belt tensioner
3 - Cooling fan drive pulley
4 W500221 Coolant pump pulley bolt (3 required)
5 8509 Coolant pump pulley
6 W500315 Power steering pump bolt (3 required)
7 3D639 Power steering pump
8 14A464 Power Steering Pressure (PSP) switch electrical
connector (part of 12B637)
9 W701219 Crankshaft Position (CKP) sensor bolt (2 required)
10 6C315 CKP sensor
11 - CKP sensor wiring harness (part of 12B637)
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Engine Front Cover

1 W500322 Engine front cover bolt
2 W705310 Engine front cover stud bolt
7 W500215 Engine front cover bolt (15 required)
8 6019 Engine front cover
Removal
tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft
timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and
the pulley are fitted together by friction, using diamond washers between the flange faces on
each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is
Engine Front Cover - Accessories 865

loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the
crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine
damage can occur.
Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector and the wiring harness pin-type
retainers.
3. NOTE: A new CKP sensor must be installed whenever the old sensor is removed.
Remove and discard the CKP sensor.
4. Remove the bolt and the accessory drive belt tensioner.
5. Remove the 3 bolts and the coolant pump pulley.
6. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
7. Remove the 3 bolts and position the power steering pump aside.
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8. NOTE: This step is needed only if a new front cover is being installed.
Using a 3 jaw puller, remove the fan drive pulley.
9. NOTE: There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up
one of the holes in the pulley with the bolt.
Remove the 21 bolts and the engine front cover.
means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak
Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings
and cautions and follow all application directions contained on the packaging of the silicone gasket
remover and metal surface prep.
Installation
1. NOTE: This step is needed only if a new front cover is being installed.
Install the fan drive pulley, using a nut and bolt with flat washers.

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. Observe all warnings and
cautions and follow all application directions contained on the packaging of the silicone gasket
remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint
areas. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
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3. Install the front cover. Tighten the 21 bolts in the sequence shown in 3 stages.
• Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in).
• Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft).
• Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).

4. Position the power steering pump and install the bolts.
• Tighten to 25 Nm (18 lb-ft).
5. Connect the PSP switch electrical connector.
6. Position the coolant pump pulley and install the 3 bolts.

7. Install the accessory drive belt tensioner and the bolt.

8. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
9. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
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10. Position a new CKP sensor and loosely install the 2 bolts.
11. Adjust the CKP with the Crankshaft Sensor Aligner, and tighten the 2 bolts.
13. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.

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Timing Drive Components
Special Tool(s)

303-465 (T94P-6256-CH)
Removal
instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing
sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are
fitted together by friction, using diamond washers between the flange faces on each part. For that
reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair
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requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be
locked in place by the special tools, otherwise severe engine damage may occur.
1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.
2. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by
pushing the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.
3. Remove the 2 bolts and the timing chain tensioner.
4. Remove the RH timing chain guide.
Timing Drive Components 870

5. Remove the timing chain.
6. Remove the 2 bolts and the LH timing chain guide.
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7. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. The tool
or the camshaft may be damaged.
If necessary, remove the 2 bolts and the camshaft sprockets.
• Use the flats on the camshaft to prevent camshaft rotation.
Installation
2. NOTICE: Do not rotate the camshafts. The valves and pistons may be damaged.

If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft
rotation and loosen the 2 sprocket bolts.
3. If removed, install the camshaft sprockets and the 2 bolts. Do not tighten the bolts at this time.
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4. Install the LH timing chain guide and the 2 bolts.
5. Install the timing chain.
6. Install the RH timing chain guide.
NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow
the next 4 steps.
7. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.
8. Using a small pick, push back and hold the ratchet mechanism.
9. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
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10. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger
in during installation.
11. Position the timing chain tensioner and install the 2 bolts.
• Remove the paper clip to release the piston.
12. Install the Camshaft Alignment Plate.

13. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. The tool
or the camshafts may be damaged.
Using the flats on the camshafts to prevent camshaft rotation, tighten the 2 bolts.
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14. Install the front cover. For additional information, refer to Engine Front Cover in this section.


Valve Train Components - Exploded View
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1 W706283 Camshaft bearing cap bolt (20 required)
2 6A284 Camshaft bearing cap (10 required)
3 6A267 Camshaft (2 required)
4 6500 Valve tappet (16 required)
5 6518 Valve spring retainer key (16 required)
6 6514 Valve spring retainer (16 required)
7 6513 Valve spring (16 required)
8 6517 Valve seal (16 required)
1. For additional information, refer to the procedures in this section.
Valve Train Components - Exploded View 875


Valve Springs
Special Tool(s)
Compressor, Valve Spring

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-472 (T94P-6565-AH)
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Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Removal
locked in place by the special tools, otherwise severe engine damage can occur.
1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
NOTICE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air
from the cylinder until the valve spring, valve spring retainer and valve spring retainer keys are
installed, or the valve can fall into the cylinder.
Remove the spark plug on the cylinder being serviced and connect the compressed air supply.
3. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
• Using the 3 Valve Spring Compressors, compress the valve spring and remove the valve
spring retainer keys, using some grease and a small screwdriver.
• Remove the valve spring retainer and the valve spring.
Valve Springs 876

Installation
1. NOTE: Check that there is no dirt or particles within the valve stem grooves. Check the seating of the
valve collets.
NOTE: Check the seating of the valve spring retainer keys.
Using the 3 Valve Spring Compressors, install the valve springs.
• Insert the valve springs and the valve spring retainers.

• Using the 3 Valve Spring Compressors, compress the valve spring and install the valve spring
retainer keys using some grease and a small screwdriver.
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2. Disconnect the compressed air supply and install the spark plug.
3. Repeat the appropriate removal and installation steps for each of the cylinders being serviced.
4. Install the valve tappets. For additional information, refer to Valve Tappets in this section.
Valve Springs 877

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Valve Springs 878


Valve Seals
Special Tool(s)

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-472 (T94P-6565-AH)
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Installer, Valve Stem Oil Seal
303-470 (T94P-6510-CH)
Remover, Valve Stem Oil Seal

303-468 (T94P-6510-AH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Removal
1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
NOTICE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air
from the cylinder until the valve spring, valve spring retainer and valve spring retainer keys are
installed, or the valve can fall into the cylinder.
Valve Seals 879

Remove the spark plug on the cylinder being serviced and connect the compressed air supply.
3. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
• Using the 3 Valve Spring Compressors, compress the valve spring and remove the valve
spring retainer keys, using some grease and a small screwdriver.
• Remove the valve spring retainer and the valve spring.
4. Using the Valve Stem Oil Seal Remover and the Slide Hammer, remove and discard the valve seal.
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Installation
1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install a new valve seal.
3. NOTE: Check that there is no dirt or particles within the valve stem grooves. Check the seating of the
valve collets.
NOTE: Check the seating of the valve spring retainer keys.
Using the 3 Valve Spring Compressors, install the valve spring.
Valve Seals 880

• Insert the valve spring and the valve spring retainer.

• Using the 3 Valve Spring Compressors, compress the valve spring and install the valve spring
retainer keys using some grease and a small screwdriver.
4. Disconnect the compressed air supply and install the spark plug.
5. Repeat the appropriate removal and installation steps for each of the cylinders being serviced.
6. Install the valve tappets. For additional information, refer to Valve Tappets in this section.
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Valve Seals 881


Valve Tappets
Material
Item Specification
XO-5W20-QSP (US);
Removal and Installation
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
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including any material created while cleaning gasket surfaces, that enters the oil passages, coolant
passages or the oil pan may cause engine failure.
NOTE: Valve tappets are select fit and the valve clearance must be checked before removing the tappets. For
additional information, refer to Valve Clearance Check in this section. If the valve clearance has already been
checked, proceed with removal.
100-02 .
2. Remove the camshafts. For additional information, refer to Camshafts in this section.
3. NOTICE: If the camshafts and valve tappets are to be reused, mark the location of the valve
tappets to make sure they are assembled in their original positions, or the engine may be
damaged.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example,
a tappet with the number 0.650 has the thickness of 3.650 mm.
Remove and inspect the valve tappets. For additional information, refer to Section 303-00 .
4. To install, reverse the removal procedure.

• Coat the valve tappets with clean engine oil prior to installation.
Valve Tappets 882

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Valve Tappets 883


Camshafts
Special Tool(s)

303-465 (T94P-6256-CH)
Material
Item Specification
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XO-5W20-QSP (US);
Removal
1. Remove the timing chain and sprockets. For additional information, refer to Timing Drive
Components in this section.
3. NOTICE: Failure to follow the camshaft loosening procedure may result in damage to the
camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for
assembly reference.
Remove the camshafts from the engine.
Camshafts 884
• Loosen the 20 camshaft bearing cap bolts, in sequence, one turn at a time.
• Repeat the first step until all tension is released from the camshaft bearing caps.
• Remove the 10 camshaft bearing caps.
• Remove the 2 camshafts.
Installation
1. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the
Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes
on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the
camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of
position, may cause severe damage to the valves and pistons.
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NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil prior to installation.
Position the camshafts and bearing caps in their original location and orientation. Loosely install the
20 bolts and tighten the bearing caps in the sequence shown in 3 stages:
• Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until snug.
• Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
2. Install the timing chain and sprockets. For additional information, refer to Timing Drive Components
in this section.
Camshafts 885
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Camshafts 886

Exhaust Manifold
Material
Item Specification
ZC-31-A
Motorcraft® Premium Gold WSS-M97B51-A1
Engine Coolant
VC-7-B (US); CVC-7-B (Canada)
Motorcraft® SAE 5W-20 WSS-M2C945-A
Premium Synthetic Blend Motor
Oil (US); Motorcraft® SAE
5W-20 Super Premium Motor Oil
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(Canada)
XO-5W20-QSP (US);
RH Splash Shield

1 - RH splash shield pushpin (5 required)
2 16034 RH splash shield
Coolant Hoses and Oil Level Indicator and Tube
Exhaust Manifold 887


1 18C266 Heater coolant hose
2 8W005 Degas bottle coolant hose
3 W500211 Oil level indicator tube bolts (2 required)
4 - Oil level indicator and tube assembly
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5 W500222 Front coolant outlet pipe bolt (2 required)
6 8B274 Upper radiator coolant hose
7 8594 Front coolant outlet pipe
Generator and Bracket
Part
1 14A464 Generator electrical connector (part of 14A280)
2 14A240 Generator battery cable boot (part of 14A280)
3 W705790 Generator battery cable terminal nut
4 14463 Generator battery cable terminal (part of 14A280)
5 13A506 Wiring harness retainer (part of 14A280) (A/C equipped
vehicles only)
6 W704432 Generator and support bracket assembly bolt (5
required)
Coolant Hoses and Oil Level Indicator and Tube 888

7 10C377 Generator and support bracket assembly
Exhaust Manifold
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1 W705443 Exhaust downpipe flange nut (2 required)
2 5E212 Exhaust downpipe
3 W708176 Coolant tube nuts (2 required)
4 8C633 Coolant tube
5 W708176 Exhaust manifold nut (7 required)
6 9430 Exhaust manifold
7 9448 Exhaust manifold gasket
8 W704474 Exhaust manifold stud (7 required)
Removal
100-02 .
3. Remove the accessory drive belt. For additional information, refer to Section 303-05 .
5. Remove the 2 exhaust downpipe flange nuts.
6. Disconnect the upper radiator hose and the degas bottle coolant hose from the front coolant outlet
pipe.
Generator and Bracket 889

7. If equipped, remove the A/C compressor. For additional information, refer to Section 412-01 .
8. Disconnect the heater coolant hose from the front coolant outlet pipe.
9. Remove the oil level indicator, the 2 bolts and the oil level indicator tube.
• Discard the O-ring seal.
10. Remove the 2 bolts and the front coolant outlet pipe.
11. Remove the 5 pushpins and position the right inner fender splash shield aside.
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12. Disconnect the generator electrical connections and, if equipped with A/C, the wiring harness retainer.
13. Remove the 5 bolts and the generator and support bracket assembly.
14. Remove the 2 nuts and position the coolant tube aside.
15. Remove the 7 nuts, the exhaust manifold and the gasket.
• Discard the exhaust manifold nuts and the gasket.
16. Remove and discard the 7 exhaust manifold-to-cylinder head studs.
17. Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 .
paths.
Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the
packaging. Observe all warnings and cautions and follow all application directions contained on the
packaging of the metal surface prep.
Installation
1. Install 7 new exhaust manifold-to-cylinder head studs.

2. Install a new exhaust manifold gasket.
3. Position the exhaust manifold and install 7 new nuts.

4. Position the coolant tube and install the 2 nuts.


5. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown, in 2
stages.
• Stage 1: Install finger-tight.
6. Connect the generator electrical connections and, if equipped with A/C, the wiring harness retainer.
• Tighten the battery cable nut to 12 Nm (106 lb-in).
7. Position the right inner splash shield and install the 5 pushpins.
8. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation.
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Using a new O-ring seal, position the front coolant outlet pipe and install the 2 bolts.
9. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, position the oil level indicator tube assembly and install the 2 bolts.
10. Install the oil level indicator.
11. Connect the heater coolant hose to the front coolant outlet pipe.
12. If equipped, install the A/C compressor. For additional information, refer to Section 412-01 .
13. Connect the upper radiator hose and the degas bottle coolant hose to the front coolant outlet pipe.
14. Install the 2 exhaust downpipe flange nuts.

15. Install the accessory drive belt. For additional information, refer to Section 303-05 .

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Cylinder Head
Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
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TA-30
Remover
ZC-30

1 14A464 EGR valve electrical connector (part of 12B637)
2 6758 Coolant hose retainer clip
3 6758 Ground cable stud bolt
4 14303 Ground cable
5 6758 EGR coolant hose position retainer clip
Cylinder Head 893

6 9Y439 EGR coolant hose

7 9E740 EGR tube
8 8548 Coolant bypass hose
9 - Cylinder head bolt (10 required)
10 6090 Cylinder head
11 6051 Cylinder head gasket
12 W701548 Cylinder block drain plug
Removal
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2. Remove the camshafts. For additional information, refer to Camshafts in this section.
3. Remove the exhaust manifold. For additional information, refer to Exhaust Manifold in this section.
4. Remove the fuel rail. For additional information, refer to Section 303-04A .
5. Remove the coolant hose retainer clip, the stud bolt and the ground cable.
6. Remove the EGR tube from the cylinder head.
7. Disconnect the EGR valve electrical connector.
8. Disconnect the EGR coolant hose and remove it from the hose bracket.
9. Disconnect the coolant bypass hose.
10. Remove the cylinder block coolant drain plug.
11. Remove the 10 bolts and the cylinder head.

• Discard the bolts.
12. Remove and discard the head gasket.
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: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all
warnings or 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.
Cylinder Head 894

Clean the cylinder head-to-cylinder block mating surfaces 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 remaining 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.
14. 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 Section 303-00 .
Installation
1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
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warnings and cautions and follow all application directions contained on the packaging of the silicone
gasket remover and metal surface prep.
Apply silicone gasket and sealant to the locations shown.
3. Install a new cylinder head gasket.
4. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts
must be installed.
Cylinder Head 895

NOTE: Lubricate the cylinder head bolts with clean engine oil.
Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown, in 5 stages.
• Stage 1: Tighten to 5 Nm (44 lb-in).

• Stage 4: Tighten an additional 90 degrees.
5. Install the cylinder block coolant drain plug.

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6. Connect the coolant bypass hose.
7. Connect the EGR coolant hose.
8. Connect the EGR valve electrical connector.
9. Connect the EGR tube to the cylinder head.

10. Position the ground strap and install the stud bolt to the cylinder head.
11. Install the coolant hose retainer clip.
12. Install the fuel rail. For additional information, refer to Section 303-04A .
13. Install the exhaust manifold. For additional information, refer to Exhaust Manifold in this section.
14. Install the camshafts. For additional information, refer to Camshafts in this section.
Cylinder Head 896

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Cylinder Head 897


Oil Filter Adapter
Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
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Remover
ZC-30
Thread Sealant with PTFE WSK-M2G350-A2
TA-24

1 W500025 Oil filter adapter bolt (4 required)
2 6714 Oil filter
3 6884 Oil filter adapter
4 9278 Engine Oil Pressure (EOP) switch
5 - EOP switch electrical connector (part of 14A280)
6 6A636 Oil filter adapter gasket
Removal
100-02 .
Oil Filter Adapter 898

3. Drain the engine oil.
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch.
6. Remove and discard the oil filter.
7. Remove the 4 bolts, the oil filter adapter and discard the gasket.
Installation
Clean and inspect the engine block and the adapter gasket mounting surfaces with silicone gasket
remover and metal surface prep. Observe all warnings and cautions and follow all application
directions contained on the packaging of the silicone gasket remover and metal surface prep.
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2. Using a new gasket, install the oil filter adapter and the 4 bolts.
3. Install a new oil filter.
4. NOTE: Apply thread sealant with PTFE to the EOP switch threads.
Install the EOP switch.
5. Connect the EOP switch electrical connector.
6. Fill the engine with clean engine oil.
7. Run the engine and check for leaks.

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Engine Oil Pressure (EOP) Switch
Material
Item Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24
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Part
1 - Engine Oil Pressure (EOP) switch electrical connector
(part of 14A280)
2 9278 EOP switch
100-02 .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch.

• To install, tighten to 15 Nm (133 lb-in).
4. NOTE: Apply thread sealant with PTFE to the sender threads.
To install, reverse the removal procedure.
Engine Oil Pressure (EOP) Switch 901

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Engine Oil Pressure (EOP) Switch 902


Oil Level Indicator and Tube
Material
Item Specification
XO-5W20-QSP (US);
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1 W500122 Oil level indicator tube bolts (2 required)
2 6750 Oil level indicator tube
3 - Oil level indicator tube O-ring seal
100-02 .
2. Remove the oil level indicator.
3. Remove the 2 bolts and the oil level indicator tube and discard the O-ring seal.
4. NOTE: Apply clean engine oil to the new O-ring seal prior to installation of the indicator tube.
To install, reverse the removal procedure.
• Install a new O-ring seal.
Oil Level Indicator and Tube 903

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Oil Level Indicator and Tube 904


Engine Lubrication Components - Exploded View
Engine and Transmission Mounts and Fasteners
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1 N621945 LH engine support insulator nut (2 required)
2 390066 Transmission mount bolts (2 required)
3 W500125 Transmission-to-oil pan bolts (4 required)
4 W500125 Transmission-to-cylinder block bolts (7 required)
Oil Pan, Oil Pump Screen and Pickup Tube

1 6730 Oil pan drain plug
2 W706284 Oil pan bolt (2 required)
3 W500224 Oil pan bolt (11 required)
4 6675 Oil pan
5 W706282 Oil pump screen and pickup tube bolt (2 required)
Engine Lubrication Components - Exploded View 905

6 6622 Oil pump screen and pickup tube

7 6625 Oil pump screen and pickup tube gasket
Oil Pump
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1 W703651 Oil pump drive chain tensioner bolt
2 6C271 Oil pump drive chain tensioner
3 6A895 Oil pump drive chain
4 W704397 Oil pump sprocket bolt
5 6652 Oil pump sprocket
6 W703647 Oil pump bolt (4 required)
7 6600 Oil pump
Oil Pan, Oil Pump Screen and Pickup Tube 906

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Oil Pump 907


Oil Pan
Special Tool(s)
3-Bar Engine Support Kit

303-F072
Lifting Eyes
303-D030 (D81L-6001-D) or equivalent
Material
Item Specification
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ZC-31-A
(Canada)
XO-5W20-QSP (US);
TA-30
Remover
ZC-30
Removal
100-02 .
2. Remove the engine cooling fan. For additional information, refer to Section 303-03 .
3. Remove the oil level indicator and tube. For additional information, refer to Oil Level Indicator and
Tube in this section.
4. NOTE: Only the LH side of the engine will be raised.
Remove the LH engine support insulator-to-engine bracket nuts.
5. Install the Lifting Eye.
Oil Pan 908

6. Install the 3-Bar Engine Support Kit and raise the LH side of the engine approximately 25 mm (1 in).
7. Remove the drain plug and drain the engine oil. Install the drain plug when finished.
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8. Detach the 2 wiring harness retainers from the engine front cover.
9. Remove the 4 engine front cover-to-oil pan bolts.
10. Remove the transmission bracket-to-transmission bolts.
11. Remove the 4 transmission-to-oil pan bolts.
12. NOTICE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts
more than 5 mm (0.19 in).
Loosen the 7 transmission-to-cylinder block bolts 5 mm (0.19 in).
13. Slide the transmission rearward 5 mm (0.19 in).
14. NOTE: If necessary, lift the rear of the transmission to remove the oil pan.
Remove the 13 oil pan bolts and the oil pan.
Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings
and cautions and follow all application directions contained on the packaging of the silicone gasket
remover and metal surface prep.
Installation
paths. Use a plastic scraping tool to remove all traces of sealant.
Oil Pan 909

NOTE: If necessary, lift the rear of the transmission to install the oil pan.
Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Position the oil pan and
install the 13 bolts finger-tight.
2. Install the 4 engine front cover-to-oil pan bolts.

3. Tighten the 13 oil pan bolts in the sequence shown.

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4. Attach the 2 wiring harness retainers to the engine front cover.
5. Slide the transmission forward and tighten the 7 transmission-to-cylinder block bolts.
6. Install the 4 transmission-to-oil pan bolts.

7. Install the transmission bracket-to-transmission bolts.

8. Lower the engine and remove the 3-Bar Engine Support Kit and the Lifting Eye.
9. Install the engine support insulator nuts.

10. Install the oil level indicator and tube. For additional information, refer to Oil Level Indicator and
Tube in this section.
11. Install the engine cooling fan. For additional information, refer to Section 303-03 .
Oil Pan 910

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Oil Pan 911


Oil Pump Screen and Pickup Tube
Material
Item Specification
ZC-31-A
Removal
1. Remove the oil pan. For additional information, refer to Oil Pan in this section.
2. Remove the 4 bolts and the oil pump screen and pickup tube.
• Discard the gasket.
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Installation
1. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and
follow all application directions contained on the packaging of the metal surface prep.
Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the
sequence shown.
2. Install the oil pan. For additional information, refer to Oil Pan in this section.
Oil Pump Screen and Pickup Tube 912

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Oil Pump Screen and Pickup Tube 913


Oil Pump
Material
Item Specification
ZC-31-A
Removal
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1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.
2. Remove the oil pump screen and pickup tube. For additional information, refer to Oil Pump Screen
and Pickup Tube in this section.
3. Remove the oil pump chain tensioner.

• Release the tension on the tensioner spring.
• Remove the bolt and the tensioner.
4. Remove the chain from the oil pump sprocket.
5. Remove the bolt and oil pump sprocket.
6. Remove the 4 bolts and the oil pump.
Installation
1. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep. Observe all
warnings and cautions and follow all application directions contained on the packaging of the metal
surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure
to follow this procedure may cause future oil leakage.
Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
Oil Pump 914

2. Install the oil pump sprocket and bolt.

3. Install the chain onto the oil pump sprocket.
4. Install the oil pump chain tensioner and bolt.

• Hook the tensioner spring around the shoulder bolt.
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5. Install the oil pump screen and pickup tube. For additional information, refer to Oil Pump Screen and
Pickup Tube in this section.
6. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.
Oil Pump 915


Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
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1 6379 Flywheel/flexplate bolt (6 required)
2 6375 Flywheel
3 6375 Flexplate
4 W500212 Crankshaft rear seal and retainer plate bolt (6 required)
5 6K318 Crankshaft rear seal and retainer plate
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View 916


Flywheel
Special Tool(s)
Locking Tool, Flywheel

303-103 (T74P-8375-A)
Removal
1. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01 .
2. Using the Flywheel Locking Tool, remove the 6 bolts and the flywheel.
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Installation
NOTE: Engine balancing is not required. Balance weights should not be installed on the new flywheel.
NOTE: Special bolts are used for installation. Do not use standard bolts.
1. Inspect the pilot bearing. Install a new pilot bearing as necessary.
2. Position the flywheel.
3. Using the Flywheel Locking Tool, install the 6 bolts in the sequence shown, in 3 stages.
4. Install the clutch disc and the pressure plate. For additional information, refer to Section 308-01 .
Flywheel 917
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Flywheel 918

Flexplate
Special Tool(s)

303-103 (T74P-8375-A)
Removal
1. Remove the transmission. For additional information, refer to Section 307-01 .
2. Using the Flywheel Locking Tool, remove the 6 bolts and the flexplate.
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Installation
1. NOTE: Engine balancing is not required. Balance weights should not be installed on the new
flexplate.
NOTE: Special bolts are used for installation. Do not use standard bolts.
Position the flexplate.
2. Using the Flywheel Locking Tool, install the 6 bolts in the sequence shown, in 3 stages.
3. Install the transmission. For additional information, refer to Section 307-01 .
Flexplate 919
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Flexplate 920

Crankshaft Rear Seal with Retainer Plate
Special Tool(s)
Installer, Crankshaft Rear Seal

303-328 (T88P-6701-B1)
Material
Item Specification
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XO-5W20-QSP (US);
Removal
1. Remove the flywheel or flexplate. For additional information, refer to Flexplate or Flywheel in this
section.
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
3. Remove the 6 bolts and the crankshaft rear seal and retainer plate as an assembly.
Installation
1. Using the Crankshaft Rear Seal Installer, position the crankshaft rear seal with retainer plate onto the
crankshaft.
2. Install the 6 crankshaft rear seal with retainer plate bolts.

• Tighten in the sequence shown to 10 Nm (89 lb-in).
Crankshaft Rear Seal with Retainer Plate 921

3. Install the oil pan. For additional information, refer to Oil Pan in this section.
4. Install the flywheel or flexplate. For additional information, refer to Flexplate or Flywheel in this
section.
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Crankshaft Rear Seal with Retainer Plate 922


Engine Support Insulators
Special Tool(s)
3-Bar Engine Support Kit

303-F072
Lifting Eyes
303-D030 (D81L-6001-D) or equivalent
RH Splash Shield
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1 - RH splash shield pushpin (5 required)
2 - RH splash shield
Engine Support Insulators
Engine Support Insulators 923


1 N621945 LH engine support insulator-to-engine bracket nut
2 W710657 LH engine support insulator-to-crossmember nut
3 6B032 LH engine support insulator
4 N621945 RH engine support insulator-to-engine bracket nut
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5 W710657 RH engine support insulator-to-crossmember nut
6 6B038 RH engine support insulator
Removal
RH and LH engine support insulators
1. Remove the front springs. For additional information, refer to Section 204-01A for Rear Wheel Drive
(RWD) vehicles or Section 204-01B for Four-Wheel Drive (4WD) vehicles.
2. Remove the cooling fan. For additional information, refer to Section 303-03 .
RH engine support insulator
3. Remove the 3 rear pushpins and position the right inner fender splash shield aside.
4. Remove the 4 RH and LH engine support insulator upper nuts.
5. Install the Lifting Eyes.
6. Raise the engine with the 3-Bar Engine Support Kit.
7. Remove the lower nut and the engine support insulator.
Installation
1. Install the engine support insulator and the engine support insulator-to-crossmember nut.
2. Lower the engine and remove the 3-Bar Engine Support Kit.

3. Remove the Lifting Eyes.
4. Install the 4 LH and RH engine support insulator-to-engine support bracket nuts.

RH engine support insulator
5. Position the right inner fender splash shield and install the 3 rear pushpins.
6. Install the cooling fan. For additional information, refer to Section 303-03 .
7. Install the front springs. For additional information, refer to Section 204-01A for RWD vehicles or
Section 204-01B for 4WD vehicles.
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REMOVAL Procedure revision date: 02/04/2011
Engine
Special Tool(s)
2,200# Floor Crane, Fold Away

300-OTC1819E or equivalent
Lifting Bracket, Engine

303-050 (T70P-6000)
Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
All vehicles
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100-02 .
2. Relieve the fuel pressure. For additional information, refer to Section 310-00 .
4. Recover the A/C system. For additional information, refer to Section 412-00 .
6. Drain the engine oil.
7. Remove the hood.
8. Remove the Air Cleaner (ACL) outlet tube. For additional information, refer to Section 303-12 .
9. Remove the upper radiator hose.
10. Remove the lower radiator hose.
Engine 926
11. Remove the fan and shroud. For additional information, refer to Section 303-03 .
12. Disconnect the 3 PCM electrical connectors. Remove the retaining nut on the harness clamp. Position
the harness on the engine.
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13. Remove the stud bolt and the ground cable.
14. Remove the heater hose assembly.

1. Disconnect the heater hoses at the bulkhead.
2. Disconnect the vacuum hose.
3. Disconnect the heater hoses at the engine and remove the assembly.
15. Disconnect the vacuum reservoir tube connection.
16. Disconnect the engine-to-degas bottle coolant bypass hose.
Engine 927
17. Disconnect the degas bottle-to-engine coolant supply hose.
18. Disconnect the A/C compressor electrical connector.
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19. Disconnect the Mass Air Flow (MAF) electrical connector.
20. Disconnect the A/C compressor manifold. Plug the lines and the compressor ports.
21. Disconnect the accelerator cable and, if equipped, the speed control cable from the Throttle Body
(TB) and the cable mounting bracket and position aside.
Engine 928
22. Disconnect and position aside the Power Steering Pressure (PSP) switch electrical connector and the
high-pressure power steering tube.
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23. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section
310-00 .
24. Detach the fuel supply tube, disconnect the electrical connectors and disconnect the evaporative purge
tube quick connect coupling. For additional information, refer to Section 310-00 .
25. Disconnect the brake booster vacuum hose and the engine ground strap.
26. Remove the 3 nuts and disconnect the positive battery cable, the negative battery cable and the
solenoid control wire at the starter.
Engine 929
27. Remove the starter wiring harness support bracket bolt and position the wiring harness aside.
28. Remove the 3 rear pushpins and position the RH splash shield aside.
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29. Disconnect the generator electrical connections.
30. Detach generator wiring pin-type retainer.
31. If equipped, disconnect the block heater electrical connector.
Engine 930
32. Disconnect the front Heated Oxygen Sensor (HO2S) electrical connector at the transmission bell
housing.
Vehicles with an automatic transmission
33. Remove the bolt and the transmission cooling tubes retaining bracket.
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All vehicles
34. Remove the bolt and the transmission dust shield.
35. Remove the 2 exhaust manifold-to-front pipe nuts.
36. Disconnect the engine wiring harness anchor and the pin-type retainer and position the wiring harness
aside.
37. Disconnect the Engine Oil Pressure (EOP) sensor electrical connector.
Engine 931
38. Remove and discard the engine oil filter.
39. Detach the wiring harness from the crossmember and disconnect the electrical connector. Route the
wiring harness to the transmission.
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40. Disconnect the rear HO2S electrical connector.
41. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. Remove the nut and route the
wiring harness over the transmission.
42. Disconnect the transmission electrical connectors and detach the wiring harness retainers.
Engine 932
43. Detach the wiring harness retainers.
Vehicles with a manual transmission
44. Disconnect the HO2S electrical connector.
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45. Disconnect the CMS electrical connector. Remove the nut and route the wiring harness over the
transmission.
46. Disconnect the transmission electrical connectors and detach the wiring harness retainers.
All vehicles
47. Route the transmission portion of the wiring harness to the engine.
48. Remove the 4 bolts and the oil filter adapter.
Engine 933
49. Remove the bolt, the 2 stud bolts and the starter.
50. Remove the starter dust shield.
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51. NOTE: Mark one stud and the flexplate for assembly reference.
Remove the 4 torque converter nuts.
All vehicles
52. NOTE: Leave the 2 side bolts in until the engine is ready to be removed.
Remove 9 of the transmission-to-engine bolts.
Engine 934
53. Remove the transmission fluid indicator and tube assembly.
All vehicles
54. Install the 2 Engine Lifting Brackets.
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55. Support the transmission with a floor jack.
56. Support the engine with the Floor Crane, using the Spreader Bar.
57. Remove the 2 side transmission-to-engine bolts.
58. NOTE: Left side shown, right side similar.
Remove the 4 engine support insulator nuts.
59. Remove the engine from the vehicle.
Engine 935
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Engine 936

DISASSEMBLY Procedure revision date: 09/01/2009
Engine
Special Tool(s)

303-465 (T94P-6256-CH)
Engine Stand
014-00232 or equivalent

303-1416
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Holding Tool, Flywheel
303-103 (T74P-8375-A)
Installer, Connecting Rod

303-462 (T94P-6136-AH)
Remover, Oil Seal

303-409 (T92C-6700-CH)
Material
Item Specification
ZC-31-A
Silicone Brake Caliper Grease and ESE-M1C171-A
Dielectric Compound
XG-3-A
instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction,
using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket
is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools,
otherwise severe engine damage may occur.
NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material,
including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages,
coolant passages or the oil pan, and cause engine failure.
NOTE: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the
engine block.
Engine 937
NOTE: For additional information, refer to the exploded views under the Engine Assembly procedure in this
section.
Vehicles with manual transmission
1. NOTICE: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed
evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch
release.
NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
Remove the 6 bolts, the clutch pressure plate and the clutch disc.
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All vehicles
2. Using the Flywheel Locking Tool, remove the 6 bolts and the flexplate or flywheel.
3. Mount the engine on a suitable engine stand.
4. Remove the drive belt.
5. Remove the engine oil level indicator, the 2 bolts and the engine oil level indicator tube.
6. Remove the 2 bolts and the front coolant outlet pipe.
Engine 938
7. Remove the 4 bolts and the A/C compressor.
8. NOTE: The generator will be removed with the accessory bracket.
Remove the 5 bolts and the accessory bracket and generator as an assembly.
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9. Remove the 4 bolts and the RH engine mount bracket.
10. Disconnect the coolant hose assembly from the thermostat housing and the PCV fitting on the intake
manifold.
11. Remove the 2 nuts and the coolant tube assembly.
Engine 939
12. Remove the 7 nuts, the exhaust manifold and gasket.

• Discard the 7 nuts and the exhaust manifold gasket.
13. Remove and discard the 7 exhaust manifold-to-cylinder head studs.
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14. Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 .
15. If equipped, remove the block heater.
16. Remove the rear coolant outlet pipe.

1. Disconnect the coolant hose.
2. Remove the 4 bolts, the rear coolant outlet pipe and discard the gasket.
17. Remove the EGR valve.

1. Disconnect the electrical connector.
2. Disconnect the coolant hose.
3. Remove the 2 bolts, the EGR valve and discard the gasket.
Engine 940
18. Remove the 4 bolts and the power steering pump.
19. Disconnect the Idle Air Control (IAC) valve, the Throttle Position (TP) sensor and the Manifold
Absolute Pressure (MAP) sensor electrical connectors.
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20. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.
21. Disconnect the Knock Sensor (KS) electrical connector, remove the 3 bolts and position the engine
wiring harness and bracket aside.
22. Disconnect the Camshaft Position (CMP) sensor electrical connector and the PCV hose.
23. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
24. Remove the 2 bolts and the EGR tube from the intake manifold.
Engine 941
25. Remove the EGR tube.

• Remove the EGR tube bracket bolt from the intake manifold.
• Disconnect the EGR tube from the cylinder head.
• Remove the EGR tube.
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damage.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
Remove the 5 bolts and the intake manifold.
• Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover.
Follow the directions on the packaging.
27. Disconnect the 4 fuel injector electrical connectors and the 2 wiring harness pin-type retainers.
28. Disconnect the ignition coil and the Cylinder Head Temperature (CHT) sensor electrical connectors.
Engine 942
29. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring
harness.
30. NOTICE: Spark plug wires must be connected correctly. Mark the spark plug wires before
removing them. Failure to follow this instruction may result in poor engine performance.
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NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wires.
With a twisting motion, disconnect the spark plug wires from the spark plugs.
31. Remove the 4 bolts and the ignition coil.
32. Remove the 3 bolts and the thermostat housing.
33. Remove the 9 bolts, the KS and the engine vent cover.
Engine 943
34. Remove the 4 bolts and the LH engine mount bracket.
35. Remove the 2 bolts, fuel rail with the injectors and the ground strap.
• Discard the fuel injector O-ring seals.
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36. Remove the 3 bolts and the coolant pump pulley.
37. Remove the 3 bolts and the coolant pump.

38. Remove the CMP sensor, CHT sensor and the spark plugs.
39. Remove the 14 fasteners and the valve cover.
Engine 944
40. Remove the 2 bolts and discard the CKP sensor.
tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket
are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are
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fitted together by friction, using diamond washers between the flange faces on each part. For
that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any
repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and
camshafts must be locked in place by the special tools, otherwise severe engine damage may
occur.
NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage
to the engine.
NOTICE: Turn the crankshaft in the normal direction of rotation only, or the engine may be
damaged.
Dead Center (TDC).
prevent engine rotation may result in engine damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Engine 945
43. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal
of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be
held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using
an air impact wrench (1/2-in drive minimum).
NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley.
The diamond washer must be replaced; remove and discard the diamond washer. If the
diamond washer is not installed, engine damage may occur.
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
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• Remove and discard the crankshaft pulley bolt and washer.
• Remove the crankshaft pulley.
• Remove the diamond washer and discard.
44. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
45. NOTE: There is one engine front cover bolt behind the cooling fan drive pulley. To remove this bolt,
align one of the cooling fan drive pulley access holes with the bolt head.
Remove the 20 bolts, the stud bolt and the engine front cover.
Engine 946
46. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by
pushing the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.
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47. Remove the 2 bolts and the timing chain tensioner.
48. Remove the RH timing chain guide.
49. Remove the timing chain.
Engine 947
50. Remove the 2 bolts and the LH timing chain guide.
51. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage
to the tool or the camshaft may occur.
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NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
Remove the 2 bolts, 2 washers and camshaft drive sprockets.
52. Remove the oil pump chain drive tensioner.

1. Release the tension on the tensioner spring.
2. Remove the 2 shoulder bolts and the tensioner.
53. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft
sprocket.
NOTE: The oil pump chain sprocket must be held in place.
Remove the bolt, the chain, sprockets and diamond washers.
Engine 948
55. NOTICE: Failure to follow the camshaft loosening procedure may result in damage to the
camshafts.
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NOTE: Mark the location and orientation of each camshaft bearing cap.
NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for
assembly reference.
Remove the camshaft bearing caps.
• Loosen the 20 camshaft bearing cap bolts in sequence shown, one turn at a time.
• Repeat the first step until all tension is released from the camshaft bearing caps.
• Remove the camshaft bearing caps.
56. Remove the camshafts.
57. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage may result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine. Foreign material, including any material
created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or
the oil pan, and cause engine failure.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder
head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged.
Engine 949
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are
torque-to-yield designed and cannot be reused.
Remove the 10 bolts and the cylinder head.
• Discard the cylinder head bolts.
58. Remove and discard the cylinder head gasket.
59. Remove the cylinder head alignment dowels.
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60. Remove the 13 bolts and the oil pan.
61. Remove the 6 bolts and the rear crankshaft seal and retainer plate.
• Discard the crankshaft rear seal and retainer plate assembly.
62. Remove the 4 bolts, the oil pump pickup tube and discard the gasket.
Engine 950
63. Remove the 4 bolts and the oil pump assembly.
64. 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 manufacturer's
instructions.
65. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in
numerical order for correct orientation for reassembly.
Remove the connecting rod cap bolts and cap.
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66. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
• Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine
block.
67. Remove the bolts in the sequence shown.

• Remove the main bearing beam.
• Discard the bolts.
68. Remove the crankshaft from the engine block.
Engine 951
69. NOTE: If the main bearings are being reused, mark them in order for correct orientation and
reassembly.
Remove the main bearings from the main bearing beam.
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70. NOTE: If the main bearings are being reused, mark them in order for correct orientation and
reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
71. NOTE: If the oil squirters are being reused, mark them in order for correct location during
reassembly.
NOTE: The front bulkhead does not have an oil squirter.
Remove the 4 oil squirters.
72. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional
information, refer to Section 303-00 .
Engine 952
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Engine 953

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 09/01/2009
Cylinder Head
Special Tool(s)

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-472 (T94P-6565-AH)
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Remover, Valve Stem Seal
303-468 (T94P-6510-AH)
Replacer, Valve Stem Seal

303-470 (T94P-6510-CH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
XO-5W20-QSP (US);
Cylinder Head - Coolant Connection and Lifting Eyes
Cylinder Head 954


1 W500033 Engine lifting eye bolts (2 required)
2 17K077 Front engine lifting eye
3 17K004 Rear engine lifting eye
4 W500015 Coolant outlet pipe bolt (4 required)
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5 9B321 Coolant outlet pipe
6 8255 Coolant outlet pipe gasket
Cylinder Head - EGR Valve, Spark Plugs, Cylinder Head Temperature (CHT) Sensor and Valves

1 W500225 EGR valve bolt (2 required)
2 9D475 EGR valve
3 9D476 EGR valve gasket
4 6G004 Cylinder Head Temperature (CHT) sensor
5 12405 Spark plug (4 required)
Cylinder Head - Coolant Connection and Lifting Eyes 955

10 6517 Valve seal (16 required)

11 6505 Intake valve (8 required)
12 6507 Exhaust valve (8 required)
Disassembly
1. Remove the 2 bolts and the engine lifting eyes.
2. Remove the Cylinder Head Temperature (CHT) sensor.
3. Remove the 4 bolts and the coolant outlet pipe.

4. Remove the 2 bolts and the EGR valve.

• Discard the EGR valve gasket.
5. Remove and discard the 4 spark plugs.
6. NOTE: Note location of the tappets prior to removal.
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Remove the 16 valve tappets.
7. Using the 3 Valve Spring Compressors, compress the valve spring and remove the valve spring
retainer keys, the valve spring retainers and the valve springs.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional
information, refer to Section 303-00 . Install new parts as necessary.
9. NOTE: Note the location of the valves if they are to be reused.
NOTE: Mark each valve if the original valves are to be used.
Remove the valves.
10. Using the Valve Stem Seal Remover and the Slide Hammer, remove and discard the valve stem seals.
11. Inspect the valves. For additional information, refer to Section 303-00 . Install new parts as necessary.
Cylinder Head - EGR Valve, Spark Plugs, Cylinder Head Temperature (CHT) Sensor and Valves956
Assembly
1. NOTE: If installing the original valves, make sure the valves are installed in the same position from
which they were removed. Coat the valve stems with clean engine oil prior to installation.
Install the valves.
2. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals.
Lubricate the valve stems and guides with clean engine oil and, using the Valve Stem Seal Replacer,
install the valve seals onto the cylinder head valve guides.
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3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the 3 Valve Spring Compressors, compress the valve spring and install the valve spring retainer
keys.
5. NOTE: Be sure to install the tappets in the same location as they were removed from.
Install the 16 valve tappets.
6. Install the CHT sensor.

7. Install 4 new spark plugs.

8. Using a new gasket, install the EGR valve and the 2 bolts.
9. Using a new gasket, install the coolant outlet pipe and the 4 bolts.
10. Install the engine lifting eyes and the 2 bolts.

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 09/01/2009
Piston
Material
Item Specification
XO-5W20-QSP (US);
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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 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 6110 Piston
Disassembly
1. Remove the piston rings from the piston.

• Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
3. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
Piston 959
Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 .
Assembly
1. NOTE: The arrow on the top of the piston points towards the front of the engine.
Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. NOTE: The piston compression upper and lower ring should be installed with the paint mark on the
outside diameter circumference of the ring to be positioned on the right side of the ring gap. The
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lower compression ring needs to be installed with the undercut side downward.
NOTE: The upper and lower compression ring gaps are not controlled for installation.
Install the piston rings onto the piston as shown.
1. Piston pin
2. Upper oil control ring gap location
3. Lower oil control ring gap location
4. Center line of the piston pin bore and the expander gap
Piston 960
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Piston 961

ASSEMBLY Procedure revision date: 02/04/2011
Engine
Special Tool(s)
Aligner, Clutch Disc

308-006 (T71P-7137-H)
Aligner, Crankshaft Sensor

303-1417

303-465 (T94P-6256-CH)
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Compressor, Piston Ring
303-D032 (D81L-6002-C) or equivalent
Dial Indicator Gauge with Holding Fixture

100-002 (TOOL-4201-C)
Engine Stand
014-0232 or equivalent


303-1416
Installer, Camshaft Front Oil Seal

303-096 (T74P-6150-A)
Installer, Connecting Rod

303-462 (T94P-6136-AH)
Installer, Crankshaft Rear Main Oil Seal

303-328 (T88P-6701-B1)

303-103 (T74P-8375-A
Spreader Bar
Engine 962
Timing Peg, Crankshaft

303-507
General Equipment
6 mm x 18 mm bolt
Material
Item Specification
High Temperature 4x4 Front Axle WSS-M1C267-A1
and Wheel Bearing Grease
XG-11
ZC-31-A
Motorcraft® Premium Gold WSS-M97B51-A1
Engine Coolant
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VC-7-B (US); CVC-7-B (Canada)
(Canada)
XO-5W20-QSP (US);
Silicone Brake Caliper Grease and ESE-M1C171-A
Dielectric Compound
XG-3-A
TA-30
Remover
ZC-30
Engine - Lower Engine Block (View 1)
Engine - Lower Engine Block (View 1) 963

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1 6010 Cylinder block
2 8575 Thermostat assembly
3 6A785 Crankcase vent oil separator
4 6A666 PCV valve
5 9278 Oil pressure sensor
6 6881 Oil filter adapter
7 6375 Flywheel
8 6K301 Crankshaft rear oil seal and retainer
9 6731 Oil filter
10 6675 Oil pan
11 6687 Oil pan baffle
12 6622 Oil pump screen and pickup tube
13 6840 Oil filter adapter gasket
Lower Engine Block (View 2)
Lower Engine Block (View 2) 964

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14 6161 Piston oil control spacer (4 required)
15 6150 Piston compression upper ring (4 required)
16 6152 Piston compression lower ring (4 required)
17 6159 Piston oil control upper segment ring (4 required)
18 6159 Piston oil control lower segment ring (4 required)
19 6140 Piston pin retainer (8 required)
20 6135 Piston pin (4 required)
21 6200 Connecting rod (4 required)
22 6211 Connecting rod upper bearing (4 required)
23 6110 Piston (4 required)
24 6211 Connecting rod lower bearing (4 required)
25 6210 Connecting rod cap (4 required)
27 6333 Cylinder block crankshaft main bearing (5 required)
28 6303 Crankshaft
29 6333 Crankshaft main bearing beam bearing (5 required)
30 6F098 Main bearing beam
Engine - Front Engine Block
Engine - Front Engine Block 965

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31 10300 Generator
32 19D629 A/C compressor
33 19E708 Front End Accessory Drive (FEAD) mounting bracket
34 8501 Coolant pump
35 8597 Coolant bypass tube
37 6600 Oil pump
38 6C271 Oil pump chain tensioner
39 6A895 Oil pump chain
40 6652 Oil pump drive gear
41 6K297 Timing chain guide
42 6268 Timing chain
43 - Timing chain tensioner arm
44 3A674 Power steering pump
45 6K254 Timing chain tensioner
46 6306 Crankshaft sprocket
47 6378 Diamond washers (2 required)
48 6019 Engine front cover
49 6700 Crankshaft front oil seal
50 3A733 Power steering pump pulley
51 8509 Coolant pump pulley
52 8610 Fan drive pulley
53 6B209 Drive belt tensioner
54 6316 Crankshaft damper
55 8620 Accessory drive belt (with A/C)
56 6A340 Crankshaft pulley bolt
Engine - Front Engine Block 966

57 6C315 Crankshaft Position (CKP) sensor

58 6C348 Drive belt pulley idler (without A/C)
59 8620 Accessory drive belt (without A/C)
Engine - Cylinder Head
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60 12281 Spark plug wire set
61 12029 Ignition coil
62 6B288 Camshaft Position (CMP) sensor
63 6766 Oil filler cap
64 6582 Valve cover
65 - Valve cover gasket
66 - Camshaft bearing cap
67 6250 Camshaft (intake)
68 6250 Camshaft (exhaust)
73 6571 Valve stem seal (16 required)
74 - Cylinder Head Temperature (CHT) sensor
Engine - Cylinder Head 967

75 12405 Spark plug (4 required)

76 18801 Radio noise suppressor
77 6065 Cylinder head bolt (10 required)
79 6505 Exhaust valve (8 required)
80 6507 Intake valve (8 required)
81 6051 Head gasket
83 6256 Camshaft sprocket (2 required)
84 9448 Exhaust manifold gasket
85 17K004 Engine lifting eye
86 6754 Oil level indicator tube assembly
87 9430 Exhaust manifold
Engine - Intake Manifold
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88 - High pressure fuel line (supply)
89 9D280 Fuel rail
90 9F593 Fuel injector (4 required)
91 - Coolant outlet adapter assembly (front)
92 - Coolant outlet adapter assembly (rear)
93 8255 Coolant outlet connector gasket
94 8A852 Coolant bypass hose and clamp assembly
95 6758 Crankcase ventilation tube
96 9E470 EGR valve-to-exhaust manifold tube
Engine - Intake Manifold 968

97 9424 Intake manifold

98 9F479 Manifold Absolute Pressure (MAP) sensor
99 9E926 Throttle Body (TB) assembly
100 9G297 Evaporative Emission (EVAP) hose
101 9F715 Idle Air Control (IAC) valve assembly
102 9D475 EGR valve
103 9D476 EGR valve mounting gasket
104 17K004 Engine lifting eye
106 6051 Cylinder head gasket
108 12A699 Knock Sensor (KS)
NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material,
including any material created while cleaning gasket surfaces may enter the cylinders, oil passages,
coolant passages or the oil pan, and cause engine failure.
NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using
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diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also
unfastened if the pulley is loosened. Therefore, the engine must be retimed each time the damper is
removed. Otherwise severe engine damage may occur.
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 Section
303-00 .
All vehicles
1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked
during disassembly.
NOTE: The front bulkhead does not have an oil squirter.
Install the 4 oil squirters.
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the
smallest diameter for each journal.

3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with
the rear face of the engine block.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
• Tighten the bolts in the sequence shown in 3 stages.
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5. Measure each crankshaft block main bearing bore diameter.

• Remove the bolts and the main bearing beam.
• Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.

7. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
• Tighten the bolts in 2 stages.
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8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
• Remove the bolts and the connecting rod cap.
• Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

11. 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.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation
as noted during disassembly.
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NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the cylinder block.
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation
as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.

15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then
position the main bearing beam in the engine block with the main bearing beam mounted flush with
the rear face of the engine block.
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17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the
front of the cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 main bearing beam bolts.
• Tighten the bolts in the sequence shown in 3 stages.

18. 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 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play
exceeds the specified range, install new parts as necessary.
19. NOTICE: 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.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with
clean engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting
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rod assemblies.
• When installing the pistons and connecting rod assemblies, the oil ring gaps must be
positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander
gap.
• The position of the upper and lower compression ring gaps are not controlled for installation.
20. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and
tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting
rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth
operation.
Install the connecting rod caps and bolts.
• Tighten the bolts in 2 stages.


21. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage
to the engine.
NOTICE: Turn the crankshaft in the normal direction of rotation only, or the engine may be
damaged.
Dead Center (TDC).
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22. Remove the timing peg plug.
23. NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC
. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must
remain in the TDC position during the crankshaft pulley removal and installation.
Install the Crankshaft Timing Peg.
Position the oil pump assembly and tighten the 4 bolts in the sequence shown, in 2 stages.

Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the
sequence shown.
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26. Using the Crankshaft Rear Main Oil Seal Installer, install the a new crankshaft rear seal and retainer
plate assembly.
27. Tighten the 6 crankshaft rear seal and retainer plate assembly bolts in the sequence shown.
paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE: Clean the sealing surface with metal surface prep and silicone gasket remover. Observe all
warnings and cautions and follow all application directions contained on the packaging of the metal
surface prep and the silicone gasket remover.

Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten
the 13 oil pan bolts in the sequence shown.
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NOTE: Observe all warnings or 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.
Clean the cylinder head-to-cylinder block mating surfaces 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 remaining 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.
30. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head and the
cylinder block distortion. For additional information, refer to Section 303-00 .
31. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

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33. Install a new cylinder head gasket.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts
must be installed.
NOTE: Lubricate the cylinder head bolts with clean engine oil.
Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown, in 5 stages.

• Stage 4: Tighten an additional 90 degrees (one-fourth turn).
• Stage 5: Tighten an additional 90 degrees (one-fourth turn).
35. NOTICE: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft
alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No.
1 cylinder are in the same position as noted in the disassembly procedure. Rotating the

camshafts, or installing the camshafts 180 degrees out of position may cause severe damage to
the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original location and orientation. Tighten the 20 bearing
cap bolts in the sequence shown in 3 stages:
• Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
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36. NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction,
with diamond washers between the flange faces on each part. The new diamond washers must
be installed correctly, or severe engine damage may result.
Install the new diamond washers and the oil pump chain and sprockets.
• The crankshaft sprocket flange must be facing away from the engine block.
37. NOTE: The oil pump chain sprocket must be held in place.
Tighten the oil pump sprocket bolt.
38. Install the oil pump chain drive tensioner shoulder bolt.

39. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt and tighten
the tensioner bolt.
40. NOTE: Sprockets must turn freely on the camshafts.
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Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this
time.
NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow
the next 4 steps.
41. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
42. Using a small pick, push back and hold the ratchet mechanism.

43. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
44. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger
in during installation.
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45. Install the timing chain.
46. Position the timing chain guides and install the 2 LH guide bolts.
47. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to apply tension to the timing
chain.

Install the Camshaft Alignment Plate in the timing slots on rear of both camshafts. Timing slots are
offset from the centerline of the camshaft.
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NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
Tighten the camshaft sprocket bolts.
Clean the engine front cover gasket surface with silicone gasket remover and metal surface prep.

Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
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Install the front cover. Tighten the bolts in the sequence shown in 3 stages.
• Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in).
• Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft).
• Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).

54. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the crankshaft front seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
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55. NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil to the seal area prior to installing.
Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
56. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

57. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during
installation of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft
pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be
installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in
drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

• Stage 2: Rotate an additional 90 degrees.
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Turn the crankshaft clockwise one and three-fourths turn.
62. Install the Crankshaft Timing Peg.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.
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64. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
• If it is not possible to install the bolt, correct the engine timing.
65. Install the Camshaft Alignment Plate to check the position of the camshafts.
• If it is not possible to install the Camshaft Alignment Plate, correct the engine timing.

67. Position a new Crankshaft Position (CKP) sensor and loosely install the 2 bolts.
68. Adjust the CKP with the Crankshaft Sensor Aligner, the tool must engage a tooth of the vibration
damper, and tighten the 2 bolts.
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71. Install the timing peg plug.


Clean the valve cover gasket sealing surface with silicone gasket remover and metal surface prep.
Observe all warnings and cautions and follow all application directions contained on the packaging of
the silicone gasket remover and metal surface prep.
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Install the valve cover and the 14 fasteners.
75. Install the following:

1. Crankshaft Position (CKP) sensor and the bolt

♦ Tighten to 7 Nm (62 lb-in).
2. Cylinder Head Temperature (CHT) sensor
3. Spark plugs
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NOTE: Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly.
Using a new O-ring seal, install the coolant pump and the 3 bolts.
77. Install the coolant pump pulley and the 3 bolts.

78. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil prior to installation.
Using new O-ring seals, install the fuel rail and fuel injectors as an assembly, the ground strap and the
bolt.
• Tighten the 2 fuel rail bolts to 25 Nm (18 lb-ft).

• Tighten ground strap bolt to 10 Nm (89 lb-in).

79. Install the left motor mount and the 4 bolts.

80. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
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Install the crankcase vent oil separator, the KS and the 9 bolts.
• Tighten the KS bolt to 20 Nm (177 lb-in).

• Tighten the 8 crankcase vent oil separator bolts to 10 Nm (89 lb-in).
81. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all
Using a new gasket, install the thermostat housing and the 3 bolts.
82. Install the ignition coil and the 4 bolts.


83. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug
boots prior to installation.
Connect the spark plug wires to the spark plugs.
84. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover
studs.
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85. Connect the ignition coil and the CHT sensor electrical connectors. Position the CHT sensor cover.
86. Connect the fuel injector electrical connectors and attach the wiring harness pin-type retainers.
87. Inspect and install new intake manifold gaskets, if necessary.

damage.
Install the intake manifold and the 5 bolts.
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89. Install the EGR tube.
• Install the EGR tube bracket and the bolt to the intake manifold.
• Connect the EGR tube to the cylinder head.
♦ Tighten to 55 Nm (41 lb-ft).
90. Connect the EGR tube to the intake manifold.

91. Attach the engine wiring harness pin-type retainers to the intake manifold.
92. Connect the CMP sensor electrical connector and the PCV hose.

93. Install the engine wiring harness connector bracket, the 3 bolts and connect the KS electrical
connector.
94. Connect the CKP sensor electrical connection and attach the wiring pin-type retainers.
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95. Connect the following electrical connectors:
• Manifold Absolute Pressure (MAP) sensor
• Throttle Position (TP) sensor
• Idle Air Control (IAC) valve
96. Install the power steering pump assembly and the 4 bolts.

Install the EGR valve.
1. Using a new gasket, position the EGR valve and install the 2 bolts.
2. Connect the coolant hose.
3. Connect the electrical connector.
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Install the rear coolant outlet pipe.
1. Using a new gasket, install the rear coolant outlet pipe and the 4 bolts.
2. Connect the coolant hose.
99. If equipped, install the block heater.
100. Install 7 new exhaust manifold-to-cylinder head studs.

101. Position a new gasket and install the exhaust manifold and 7 new nuts.

102. Position the coolant tube assembly and install the 2 nuts.
103. Connect the coolant hose to the thermostat and the PCV fitting on the intake manifold.
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104. Position the right motor mount and install the 4 bolts.
105. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown, in 2
stages.
• Stage 1: Install finger-tight.
106. Position the A/C compressor and install the 4 bolts.


107. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation.
Position the front coolant outlet pipe and install the 2 bolts.
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108. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the engine oil level indicator tube and the bolt.
109. Install the accessory drive belt.
110. Using the Spreader Bar and the Floor Crane, remove the engine from the Engine Stand.
111. Position the flywheel or the flexplate and loosely install the 6 bolts.
112. Using the Flywheel Locking Tool, tighten the 6 bolts in the sequence shown, in 3 stages.

Vehicles with manual transmission
113. Lubricate the transmission input shaft pilot bearing with front axle grease.
114. Adjust the clutch pressure plate.
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1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the
adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
115. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
116. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the 6 bolts. Tighten the bolts in a star pattern sequence.

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INSTALLATION Procedure revision date: 02/18/2011
Engine
Special Tool(s)

Lifting Bracket, Engine

303-050 (T70P-6000)
Spreader Bar
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Material
Item Specification
XO-5W20-QSP (US);
All vehicles
1. Position the engine in the vehicle. If equipped with an automatic transmission, make sure the index
marks on the torque converter stud and flexplate made during removal are lined up.
2. Install the 2 side transmission-to-engine bolts.
3. NOTE: Left side shown, right side similar.
Install the 4 engine support insulator nuts.
4. Remove the floor jack from the transmission.
5. Remove the Floor Crane, the Spreader Bar and the Engine Lifting Brackets.
Engine 999
6. NOTICE: Only rotate the engine in a clockwise direction or engine damage may occur.
Install the 4 torque converter nuts.
7. Install the transmission fluid indicator and tube assembly.
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All vehicles
8. Install the remaining 9 transmission-to-engine bolts.

9. Position the oil filter adapter and install the 4 bolts.

10. Install the starter dust shield.
Engine 1000
11. Install the starter, the bolt and the 2 stud bolts.
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13. Connect the Engine Oil Pressure (EOP) sensor electrical connector.
14. Attach the wiring harness retainers.
15. Attach the wiring harness retainers and connect the transmission electrical connectors.
Engine 1001
16. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the
Catalyst Monitor Sensor (CMS) electrical connector.
17. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
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Vehicles with a manual transmission
18. Attach the wiring harness retainers and connect the transmission electrical connectors.
19. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the
CMS electrical connector.
20. Connect the HO2S electrical connector.
Engine 1002
All vehicles
21. Connect the electrical connector and attach the wiring harness retainer to the crossmember.
22. Position the exhaust front pipe and install the 2 nuts.
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23. Position the transmission dust shield and install the bolt.
24. Install the transmission cooling tubes retaining bracket and the bolt.
All vehicles
Engine 1003
25. Position the engine wiring harness and install the anchor and the pin-type retainer.
26. If equipped, connect the block heater electrical connector.
27. Attach the generator wiring pin-type retainer.
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28. Connect the generator electrical connections.
29. Position the RH splash shield and install the 3 rear pushpins.
30. Position the starter wiring harness and install the support bracket and the bolt.
Engine 1004
31. Connect the following starter motor electrical connections.

• Install the solenoid control wire and nut.
• Install the negative battery cable and nut.
• Install the positive battery cable at the starter and the nut.
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32. Connect the brake booster vacuum hose and the engine ground strap.
33. Connect the electrical connectors, the fuel supply tube and the evaporative purge tube quick connect
coupling. For additional information, refer to Section 310-00 .
34. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section 310-00
.
35. NOTE: Install a new nylon O-ring seal.
Connect the power steering high-pressure tube and the Power Steering Pressure (PSP) switch
electrical connector.
Engine 1005
36. Connect the accelerator cable and, if equipped, the speed control cable to the Throttle Body (TB) and
the cable mounting bracket.
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37. Remove the plugs and connect the A/C compressor manifold.
38. Connect the Mass Air Flow (MAF) sensor electrical connector.
39. Connect the A/C compressor electrical connector.
Engine 1006
40. Connect the coolant reservoir-to-engine supply hose.
41. Connect the engine-to-coolant reservoir bypass hose.
42. Connect the vacuum reservoir tube.
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43. Install the heater hose assembly.
1. Connect the heater hoses to the heater core.
2. Connect the vacuum hose.
3. Connect the heater hoses to the engine.
44. Install the ground strap and stud bolt.

45. Position the PCM harness, install the harness retaining nut and connect the 3 PCM electrical
connectors.
• Tighten the harness retainer nut to 4 Nm (35 lb-in).
Engine 1007
46. Install the lower radiator hose.
47. Install the fan shroud. For additional information, refer to Section 303-03 .
48. Install the upper radiator hose.
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49. Install the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
50. Install the hood.
54. Fill and bleed the power steering system. For additional information, refer to Section 211-00 .
55. Evacuate and charge the A/C system. For additional information, refer to Section 412-00 .
Engine 1008
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Engine 1009

Item Specification Fill Capacity: 2010 Ranger Workshop Manual

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2010 Ranger Workshop Manual

SECTION 303-01A: Engine - 2.3L 2010 Ranger Workshop Manual