SECTION 303-01: Engine — 5.

4L (3V) 2007 Expedition/Navigator Workshop Manual

ASSEMBLY Procedure revision date: 08/28/2008

Engine

Special Tool(s)
Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)

Installer, Connecting Rod

303-442 (T93P-6136-A)

Compressor, Valve Spring

303-1039

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)

Installer, Crankshaft Front Seal

303-635

Installer, Front Cover Seal

303-335 (T88T-6701-A)

Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent
Installer, Crankshaft Rear Seal
303-518 (T95P-6701-DH)

Installer, Crankshaft Oil Slinger

303-517 (T95P-6701-CH)

Installer, Crankshaft Rear Seal

303-516 (T95P-6701-EH)

Impact Slide Hammer

100-001 (T50T-100-A)

Alignment Pins, Cylinder Head

303-1040 (SR-015486)

Lifting Bracket, Engine

303-F047 (014-00073) or
equivalent

Locking Tool, Cam Phaser

Sprocket
303-1046
Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Silicone Gasket Remover —
ZC-30
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent (US M97B51-A1
only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Hydraulic Chain Tensioner —
Retaining Clip
1L3Z-6P250-AA

Engine — Upper End

 Part
Item Number Description
1 12B637 Engine wiring harness
2 6A505 Valve cover — LH
3 6750 Oil level indicator
4 N605892 Oil level indicator tube bolt
5 6K873 Oil level indicator tube
6 N807834 Camshaft bearing cap bolt (10 required)
7 6B280 Camshaft bearing cap (4 required)
8 6C255 Camshaft — LH
9 6529 Roller follower (24 required)
10 6518 Valve spring retainer key (48 required)
11 6514 Valve spring retainer (24 required)
12 6513 Valve spring (24 required)
13 6A517 Valve stem seal (24 required)
14 6C501 Hydraulic lash adjuster (24 required)
15 6279 Camshaft phaser sprocket bolt — LH
16 6C524 Camshaft phaser sprocket — LH
17 6B284 Camshaft bearing cap
18 12405 Spark plug (4 required)
19 12A366 Ignition coil (4 required)
20 6065 Cylinder head bolt (20 required)
21 W707747 Exhaust manifold stud (8 required)
22 9Y431 Exhaust manifold gaskets (2 required)
23 9431 Exhaust manifold — LH
24 W701706 Exhaust manifold nut (8 required)
25 6507 Intake valve (16 required)
26 6505 Exhaust valve (8 required)
27 6083 Cylinder head gasket — LH
28 W701520 Variable camshaft timing (VCT) oil control solenoid
assembly bolt (2 required)
29 6C261 VCT oil control solenoid assembly
30 6050 Cylinder head — LH
31 14B102 Cylinder head temperature (CHT) sensor jumper
harness
32 W701571 Heater outlet tube stud bolt
33 18663 Heater outlet tube
34 6051 Cylinder head gasket — RH
35 6049 Cylinder head — RH
36 9Y431 Exhaust manifold gasket (2 required)
37 9430 Exhaust manifold — RH
38 W701706 Exhaust manifold nut (8 required)
39 W707747 Exhaust manifold stud (8 required)
40 6C260 VCT oil control solenoid assembly
41 W701520 VCT oil control solenoid assembly bolt (2 required)
42 6279 Camshaft phaser sprocket bolt — RH
43 6C524 Camshaft phaser sprocket — RH
44 6B284 Camshaft bearing cap
45 N807834 Camshaft bearing cap bolt (10 required)
46 6B280 Camshaft bearing cap (4 required)
47 6251 Camshaft — RH
48 12405 Spark plug (4 required)
49 12A366 Ignition coil (4 required)
50 W706175 Ignition coil bolt (8 required)
51 6582 Valve cover — RH
52 6765 Oil fill adapter
53 6766 Oil fill adapter cap
54 6758 Crankcase ventilation tube
55 W503282 Coolant crossover tube bolt (3 required)
56 W503279 Thermostat housing bolt (2 required)
57 8594 Thermostat housing
58 N806807 Thermostat O-ring seal
59 8575 Thermostat
60 8C369 Coolant crossover tube
61 9A474 Intake manifold vacuum tube and support bracket
62 W709775 Intake manifold bolt (10 required)
63 9Y451 Intake manifold assembly
64 6K817 Positive crankcase ventilation (PCV) tube
65 W500204 PCV heater element assembly bolt (2 required)
66 9F624 PCV heater element assembly

Engine — Front End

Item Part Number Description
1 N804758 Radio ignition interference capacitor nut
2 18801 Radio ignition interference capacitor
3 6C086 Engine front cover
4 W503282 Timing chain guide bolt— RH (2 required)
5 6L266 Timing chain tensioner — RH
6 N606543 Timing chain tensioner bolt — RH (2 required)
7 6268 Timing chain — RH
8 6M256 Timing chain guide — RH
9 N606543 Timing chain tensioner bolt — LH (2 required)
10 6M269 Timing chain tensioner — LH
11 6M274 Tensioner arm — LH
12 N605892 Timing chain guide upper bolt — LH
13 6306 Crankshaft sprocket
14 6B274 Timing chain guide — LH
15 N606527 Timing chain guide lower bolt — LH
16 6268 Timing Chain — LH
17 6K255 Tensioner arm — RH
18 12A227 Ignition pulse wheel
19 W707225 Power steering pump stud bolt
20 W706447 Power steering pump bolt (2 required)
21 3A696 Power steering pump assembly
22 W706605 Engine front cover bolt
23 N808529 Engine front cover stud bolt (2 required)
24 N806177 Engine front cover bolt (9 required)
25 6C315 Crankshaft position (CKP) sensor
26 N806155 CKP sensor bolt
27 19A216 Accessory drive belt idler pulley
28 N808102 Accessory drive belt idler pulley bolt
29 6700 Crankshaft front seal
30 6316 Crankshaft pulley
31 N806165 Crankshaft pulley washer
32 W701512 Crankshaft pulley bolt
33 8A528 Coolant pump pulley
34 N806282 Coolant pump pulley bolt (4 required)
35 N808794 Coolant pump bolt (4 required)
36 8501 Coolant pump
37 N808102 Accessory drive belt idler pulley bolt
38 19A216 Accessory drive belt idler pulley
39 N806155 Camshaft position (CMP) sensor bolt (2 required)
40 6B288 CMP sensor (2 required)
41 W709573 Engine front cover stud bolt (3 required)

Engine — Lower End

Item Part Number Description
1 6150 Upper compression ring (8 required)
2 6152 Lower compression ring (8 required)
3 6159 Outer oil control ring (8 required)
4 6161 Inner oil control ring (8 required)
5 6159 Outer oil control ring (8 required)
6 6140 Piston pin retainer (16 required)
7 6135 Piston pin (8 required)
8 6110 Piston (8 required)
9 6200 Connecting rod assembly (8 required)
10 6211 Connecting rod bearing (8 required)
11 6K318 Crankshaft rear seal retainer plate
12 N806155 Crankshaft rear seal retainer plate bolt (6 required)
13 6701 Crankshaft rear seal
14 6310 Crankshaft oil slinger
15 6375 Flexplate
16 N806168 Flexplate bolt (8 required)
17 6714 Oil filter
18 6890 Oil filter threaded adapter
19 N806156 Oil filter adapter bolt (4 required)
20 9278 Engine oil pressure (EOP) switch
21 6881 Oil filter adapter
22 6A636 Oil filter adapter gasket
23 W701605 Oil pan bolt (16 required)
24 6675 Oil pan
25 6710 Oil pan gasket
26 N605904 Oil pump screen and pickup tube bolt
27 N806155 Oil pump screen and pickup tube bolt (2 required)
28 6622 Oil pump screen and pickup tube
29 N806180 Oil pump screen and pickup tube spacer
30 6K258 Crankshaft main bearing cap stud
31 6345 Crankshaft main bearing cap bolt (9 required)
32 6A346 Crankshaft main bearing dowel (10 required)
33 6C357 Crankshaft main bearing cap bolt (10 required)
34 6325 Crankshaft main bearing cap (5 required)
35 6A338 Crankshaft bearing — lower (5 required)
36 6K302 Crankshaft thrust washer — lower
37 6303 Crankshaft
38 N806201 Crankshaft key
39 6A341 Crankshaft thrust washer — upper (2 required)
40 6333 Crankshaft bearing — upper (4 required)
41 6W337 Crankshaft bearing — upper
42 6210 Connecting rod cap (8 required)
43 6211 Connecting rod bearing (8 required)
44 6621 Oil pump
45 N806183 Oil pump bolt (3 required)
46 6010 Cylinder block
47 W500225 Knock sensor bolt (2 required)
48 12A699 Knock sensor (2 required)
All vehicles

1. Record the main bearing code found on the front of the engine block.

2. Record the main bearing code found on the back of the crankshaft.

3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for each main bearing.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft
main bearing code.
Read down the column below the engine block main bearing code letter, and across the row
next to the crankshaft main bearing code letter, until the 2 intersect. This is the required
bearing grade for the number one crankshaft main bearing.
As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the
correct bearing grade for this main bearing is a "2".
Repeat this process for the remaining 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit
Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. 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.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine
oil.

6. NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust
washers until the crankshaft is installed. Refer to the following 2 steps.

Install the crankshaft onto the upper crankshaft main bearings.

7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft thrust surface).

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the
No. 5 main boss.

8. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft surface).

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No.
5 main boss.
 9. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft
surface).

Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil
grooves facing the crankshaft surface.

10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean
engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as
possible, alternately draw the cap down evenly using the cap fasteners.

11. Install the dowel pins so the flat sides face the crankshaft.
12. Install the vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown.
Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
13. Install the side bolts and tighten them in 2 stages, in the sequence shown.
Stage 1: Tighten to 30 Nm (22 lb-ft).
Stage 2: Tighten an additional 90 degrees.
14. Assemble the 8 pistons. For additional information, refer to Piston in this section.

15. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around
the circumference of the piston.
16. Make sure the dimple in the piston faces the front of the engine.

17. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons.
Only one connecting rod, rod bearing and piston is shown.

Use the special tools to install the connecting rod with the upper connecting rod bearing in place.
Lubricate the piston and ring with clean engine oil
Lubricate the rod bearings with clean engine oil.
18. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the special tools.

19. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod
ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod, and install the new bolts loosely.

20. NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.

Stage 1: Tighten to 43 Nm (32 lb-ft).
Stage 2: Tighten an additional 105 degrees.
21. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to
Section 303-00 .

22. Position the oil pump and install the bolts.

Tighten to 10 Nm (89 lb-in).

23. Install the oil pump screen and pickup tube spacer.
Tighten to 25 Nm (18 lb-ft).
24. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.

Position the oil pump screen and pickup tube and install the bolts.
Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

25. Position the crankshaft keyway at the 11 o'clock position.

26. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface
and cylinder bore.

NOTICE: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted.
The gasket must be installed dry.

NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-
to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and
install the cylinder head bolts loosely.

27. NOTE: RH shown, LH similar.

Tighten the bolts in 3 stages, in the sequence shown.

Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
Stage 3: Tighten an additional 90 degrees.
28. Remove the special tool from the LH cylinder head.

29. Remove the special tool from the RH cylinder head.

30. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

31. Install the LH and RH camshafts.

Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

32. NOTE: LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.

Lubricate the camshaft bearing caps with clean engine oil.
Position the front camshaft bearing cap.
Position the remaining camshaft bearing caps.
Install the bolts loosely.
Tighten to 10 Nm (89 lb-in) in the sequence shown.
33. NOTICE: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if
mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.

34. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.

NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or
damage may occur to the camshaft or camshaft phaser and sprocket.
 NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.

35. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons
will result.

NOTICE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks,
tears, separation from the tensioner body or permanent compression of the seal bead is
observed, install a new tensioner or engine damage may occur.

Compress the tensioner plunger, using a vise.

36. Install a retaining clip on the tensioner to hold the plunger in during installation.
37. Remove the tensioner from the vise.

38. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as
timing marks.

39. Install the crankshaft sprocket, making sure the flange faces forward.

40. Install the 4 bolts and the LH and RH timing chain guides.
Tighten to 10 Nm (89 lb-in).
41. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing
mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

42. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2
copper (marked) chain links.
43. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner
and bolts.
Tighten to 25 Nm (18 lb-ft).

44. Remove the retaining clip from the LH timing chain tensioner.

45. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing
mark on the sprocket with the single copper (marked) chain link.
46. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for
the RH camshaft.

Position the RH timing chain on the camshaft phaser and sprocket with the timing mark positioned
between the 2 copper (marked) chain links.

47. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner
and bolts.
Tighten to 25 Nm (18 lb-ft).
48. Remove the retaining clip from the RH timing chain tensioner.

49. As a post-check, verify correct alignment of all timing marks.

50. Install the crankshaft sensor ring on the crankshaft.

51. Using the special tool, install all of the camshaft roller followers.
Lubricate the camshaft roller followers with clean engine oil prior to installation.
52. 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.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on
the packaging. 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.

NOTE: Make sure that the engine front cover gasket are in place on the engine front cover before
installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the
locations shown.
53. Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto
the dowels. Install the fasteners finger-tight.

54. Tighten the engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56

55. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the LH camshaft position (CMP) sensor and the bolt.

Tighten to 10 Nm (89 lb-in).
56. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the RH CMP sensor and the bolt.

Tighten to 10 Nm (89 lb-in).

57. NOTICE: Do not rotate the coolant pump housing once the coolant pump has been positioned
in the cylinder block. Damage to the O-ring seal will occur.

Position the coolant pump and install the bolts loosely.

Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the
coolant pump.
58. Tighten the 4 coolant pump bolts.
Tighten to 25 Nm (18 lb-ft).

59. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

60. Using the special tools, install a new crankshaft front seal into the engine front cover.

61. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

62. Use the special tool to install the crankshaft pulley.

63. Tighten the new crankshaft pulley bolt in 4 stages.

Stage 1: Tighten to 90 Nm (66 lb-ft).
Stage 2: Loosen 360 degrees.
Stage 3: Tighten to 50 Nm (37 lb-ft).
Stage 4: Tighten an additional 90 degrees.

64. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
 Install the crankshaft position (CKP) sensor and the bolt.
Tighten to 10 Nm (89 lb-in).

65. Position the accessory drive belt tensioner and install the 3 bolts.
Tighten to 25 Nm (18 lb-ft).

66. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
Tighten to 25 Nm (18 lb-ft).

67. 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.
 NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts.

Tighten to 25 Nm (18 lb-ft).

68. NOTE: LH shown, RH similar.

Install 16 new exhaust manifold studs.

Tighten to 12 Nm (9 lb-ft).

69. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
 Tighten to 25 Nm (18 lb-ft).

70. Position the exhaust manifold heat shield and install the 3 bolts.
Tighten to 10 Nm (89 lb-in).

71. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.
Tighten to 63 Nm (46 lb-ft).

72. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
Tighten to 25 Nm (18 lb-ft).
73. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
Tighten to 63 Nm (46 lb-ft).

74. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools cause scratches and gouges which make leak
paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.

75. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Early build vehicles

76. NOTICE: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence
shown.
Tighten to 10 Nm (89 lb-in).

Late build vehicles

77. NOTICE: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
 Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence
shown.
Tighten to 10 Nm (89 lb-in).

All vehicles

78. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools cause scratches and gouges which make leak
paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.

79. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Early build vehicles

80. NOTICE: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence
shown.
Tighten to 10 Nm (89 lb-in).

Late build vehicles

81. NOTICE: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
 Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence
shown.
Tighten to 10 Nm (89 lb-in).

All vehicles

82. Install the oil level indicator tube and the bolt.
Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
Tighten to 10 Nm (89 lb-in).

83. NOTE: Do not reuse the O-ring seals.

 NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.

84. Install the coolant tube stud bolt.

Tighten to 10 Nm (89 lb-in).

85. Install the 2 knock sensors (KS) and the bolts.

Tighten to 20 Nm (15 lb-ft).

86. Position the electrical harness on the engine assembly and connect the engine wiring harness
retainers to the valve cover studs.
87. NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.

Tighten to 6 Nm (53 lb-in).

88. Install the LH radio ignition interference capacitor and the nut.
Tighten to 25 Nm (18 lb-ft).

89. Connect the 2 engine wiring harness retainers to the LH valve cover studs.

90. Connect the cylinder head temperature (CHT) sensor electrical connector.
91. Connect the 4 RH ignition coil electrical connectors.

92. Connect the electrical connector retainer to the coolant tube.

93. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
94. NOTE: RH shown, LH similar.

Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connector.

95. Install the RH radio ignition interference capacitor and the nut.
Tighten to 25 Nm (18 lb-ft).

96. NOTE: RH shown, LH similar.

Disconnect the RH and LH CMP sensor electrical connectors.

 97. Connect the 2 coolant hoses to the oil filter adapter.

98. Install the special tool.

99. Using a suitable floor crane, remove the engine from the engine stand.

100. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the aluminum retainer plate. These tools cause scratches and gouges, which
make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer
plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
101. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer
sealing surface.

102. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

103. Tighten the bolts in the sequence shown.

Tighten to 10 Nm (89 lb-in).
104. 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.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.

105. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing
surface.

106. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
107. Install the oil pan gasket and the oil pan and loosely install the bolts.

108. Tighten the bolts in 3 stages, in the sequence shown.

Stage 1: Tighten to 2 Nm (18 lb-in).
Stage 2: Tighten to 20 Nm (15 lb-ft).
Stage 3: Tighten an additional 60 degrees.
109. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the special tools, install a new crankshaft rear seal.

110. Using the special tools, install a new crankshaft rear oil slinger.
111. Install the flexplate and the 8 bolts in the sequence shown.
Tighten to 80 Nm (59 lb-ft).