Thursday, March 15, 2012

How to replace Cylinder Head For 5.4L Engine On Ford Mustang?

The details to replace Cylinder Head For 2010 Ford Mustang 5.4L engine and other Mustang years is as follows:----


Removal & Installation

5.4L Engine
Specific to:
Ford Mustang 2009-2010

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

Both cylinder heads
5.4L Engine
  1. Remove the engine from the vehicle.
  2. Remove the 8 flywheel bolts.
    NOTE
    The flywheel is a press fit on the crankshaft pilot. Do not use screwdrivers or prybars to remove the flywheel or damage to the flywheel or engine may occur.
  3. Remove the flywheel.
    1. Install 2 of the removed flywheel bolts in the 2 holes shown on the flywheel flange.
    2. Tighten the 2 bolts evenly to push the flywheel off the crankshaft pilot.

      Click image to see an enlarged view
      Fig. Locating where to install 2 of the removed flywheel bolts
  4. Remove the engine/transmission spacer plate.
  5. Mount the engine on a suitable work stand.
  6. Disconnect the coolant hose from the thermostat housing.
  7. Remove the coolant tube bracket nut.
  8. Disconnect the 2 coolant vent hoses from the intake manifold.
  9. Disconnect the 2 upper radiator hoses from the intake manifold.
  10. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
  11. Remove the 2 nuts and the thermostat housing assembly.
  12. Disconnect the coolant hose from the Charge Air Cooler (CAC).
  13. Loosen the 4 coolant pump pulley bolts.
  14. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
  15. Remove the bolt, Supercharger (SC) drive belt tensioner and the SC drive belt.
  16. Remove the power steering tube bracket nut.
  17. Remove the power steering tube bracket bolt.
  18. Remove the 2 power steering reservoir bracket bolts.
  19. Remove the 3 bolts and the power steering pump and reservoir assembly.

    Click image to see an enlarged view
    Fig. Removing the 3 bolts and the power steering pump and reservoir assembly
  20. Disconnect the generator electrical connector.
  21. Remove the stud bolt, 2 bolts and the alternator.
  22. Remove the bolt and the accessory drive belt tensioner.
  23. Remove the stud bolt and the accessory drive belt idler pulley (smooth).
  24. Remove the bolt and the accessory drive belt idler pulley (grooved).
  25. Remove the 4 bolts and the coolant pump pulley.
  26. Remove the 3 bolts and the 3 SC drive belt idler pulleys.

    Click image to see an enlarged view
    Fig. Removing the SC drive belt idler pulleys
  27. Disconnect the 2 EGR tube fittings. Remove the EGR tube.
  28. Disconnect and remove the crankcase ventilation tube.
  29. Disconnect the TP sensor electrical connector.
  30. Remove the 4 bolts and the TP and spacer assembly. Discard the gasket.
  31. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
  32. Detach the 2 wiring harness pin-type retainers (1 shown) from the coolant tube assembly bracket.

    Click image to see an enlarged view
    Fig. Detaching pin type retainers from the coolant tube assembly bracket
  33. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.
  34. Disconnect the bubbler tube from the SC.

    Click image to see an enlarged view
    Fig. Disconnecting the bubbler tube from the SC
  35. Remove the 2 bolts and the wiring harness retaining bracket.
  36. Detach the 2 wiring harness pin-type retainers.
  37. Disconnect the PCV valve electrical connector.
  38. Disconnect the 4 RH fuel injector electrical connectors.
  39. Disconnect the fuel rail pressure and temperature sensor electrical connector.
  40. Remove the nut and the RH radio interference capacitor.
  41. Disconnect the EGR valve electrical connector.
  42. Detach the wiring harness from the RH coil-on-plug cover stud bolt.
  43. Detach the wiring harness retainers from the RH valve cover stud bolts.
  44. Remove the nut and the A/C tube support bracket.
  45. Remove the bolt, stud bolt and the RH coil-on-plug cover.

    Click image to see an enlarged view
    Fig. Removing the RH coil on plug cover
  46. Disconnect the 4 RH coil-on-plug electrical connectors. Remove the 4 RH coil-on-plugs.

    Click image to see an enlarged view
    Fig. Removing the 4 RH coil on plugs
  47. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
  48. Disconnect the Camshaft Position (CMP) sensor electrical connector.
  49. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
  50. Disconnect the 4 LH fuel injector electrical connectors.
  51. Remove the nut and the LH radio interference capacitor.
  52. Detach the wiring harness retainers from the LH valve cover stud bolts.
  53. Remove the 2 bolts and the LH coil-on-plug cover.

    Click image to see an enlarged view
    Fig. Removing the LH coil on plug cover
  54. Disconnect the 4 LH coil-on-plug electrical connectors. Remove the 4 LH coil-on-plugs.

    Click image to see an enlarged view
    Fig. Removing the 4 LH coil on plugs
  55. Remove the wiring harness assembly from the engine.
  56. Disconnect the intake manifold-to-coolant tube assembly hose.
    NOTE
    If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  57. Remove the 14 bolts and the intake manifold assembly. Remove and discard the 2 intake manifold gaskets.

    Click image to see an enlarged view
    Fig. Removing the intake manifold assembly
  58. Remove the 3 coolant tube assembly bolts.
  59. Remove the 6 bolts and the oil cooler. Remove and discard the oil cooler gasket.

    Click image to see an enlarged view
    Fig. Removing the oil cooler
  60. Remove the 8 bolts and the oil filter adapter. Remove and discard the oil filter adapter gasket.

    Click image to see an enlarged view
    Fig. Removing the oil filter adapter
  61. Remove the oil level indicator, the bolt and the oil level indicator tube. Remove and discard the oil level indicator tube O-ring seal.
    NOTE
    The RH engine support insulator bracket must be removed to access the RH block drain plug.
  62. If equipped with a cylinder block drain, remove the stud bolt, 3 bolts and the RH engine support insulator bracket.

    Click image to see an enlarged view
    Fig. Removing the RH engine support insulator bracket
  63. If equipped, remove the LH and RH block drain plugs.

    Click image to see an enlarged view
    Fig. Removing the drain plug (LH shown, RH similar)
  64. Remove the 8 bolts, 2 stud bolts and the valve covers. Remove and discard the gaskets.
    NOTE
    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.

    1. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    2. Inspect the mating surfaces.

      Click image to see an enlarged view
      Fig. Removing the valve cover
  65. Remove the bolt and the Crankshaft Position (CKP) sensor.
  66. Remove the bolt and the CMP sensor.
  67. Remove the 4 bolts and the coolant pump.
  68. Using the Strap Wrench, remove the crankshaft pulley bolt and the washer. Discard the bolt.
  69. Using the 3 Jaw Puller, remove the crankshaft pulley.
  70. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front seal
  71. Remove the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.

    Click image to see an enlarged view
    Fig. Removing the 2 oil pan to engine front cover bolts and the 2 oil pan to engine front cover stud bolts
  72. Remove the 16 bolts and the engine front cover.
    1. Remove and discard the engine front cover gaskets.
      NOTE
      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.
    2. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    3. Inspect the mating surfaces.
      NOTE
      Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.


      NOTE
      Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.



      Click image to see an enlarged view
      Fig. Removing the engine front cover
  73. Remove the 8 spark plugs.
    NOTE
    If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  74. Using the Valve Spring Compressor, compress the valve spring and remove the roller follower.
  75. Repeat the previous step to remove all the roller followers.
    NOTE
    If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  76. Remove the hydraulic lash adjusters. Inspect the hydraulic lash adjusters.

    Click image to see an enlarged view
    Fig. Removing the hydraulic lash adjusters
  77. Remove the crankshaft sensor ring.
  78. Remove the crankshaft washer.
  79. Remove the 2 bolts and the RH primary timing chain tensioner.
  80. Remove the RH primary timing chain tensioner arm.
  81. Remove the RH primary timing chain.
  82. Remove the 2 bolts and the RH primary timing chain guide.
  83. Remove the LH primary timing chain tensioner arm.
  84. Remove the LH primary timing chain.
  85. Remove the 2 bolts and the LH primary timing chain guide.
  86. Remove the crankshaft sprocket.

LH cylinder head
  1. Remove 8 nuts and the LH exhaust manifold. Discard the nuts and gaskets.

    Click image to see an enlarged view
    Fig. Removing the LH exhaust manifold
  2. Clean and inspect the LH exhaust manifold.
  3. Remove and discard the 8 LH exhaust manifold studs.

RH cylinder head
  1. Remove 8 nuts and the RH exhaust manifold. Discard the nuts and gaskets.

    Click image to see an enlarged view
    Fig. Removing the RH exhaust manifold
  2. Clean and inspect the RH exhaust manifold.
  3. Remove and discard the 8 RH exhaust manifold studs.
  4. Remove the 3 coolant tube assembly bolts.

Both cylinder heads

NOTE
The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.


NOTE
Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.


NOTE
The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.


NOTE
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.


NOTE
Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

  1. Remove the 10 bolts and the cylinder head. Discard the bolts. Remove and discard the cylinder head gaskets.
    NOTE
    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.


    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.



    Click image to see an enlarged view
    Fig. Removing the cylinder head (LH shown, RH similar)
  2. 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.
  3. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
To install:
  1. Install the head gasket over the dowel pins.
    NOTE
    Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. Failure to follow these instructions may result in engine damage.


    NOTE
    The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. 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
    The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.


    NOTE
    Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. Failure to follow these instructions may result in engine damage.
  2. Install the cylinder head on the dowels and the head gasket. Loosely install the new bolts.
  3. Tighten the new cylinder head bolts in 5 stages in the sequence shown.
    1. Stage 1: Tighten to 177 inch lbs. (20 Nm).
    2. Stage 2: Tighten to 37 ft. lbs. (50 Nm).
    3. Stage 3: Tighten to 59 ft. lbs. (80 Nm).
    4. Stage 4: Tighten an additional 90°.
    5. Stage 5: Tighten an additional 90°.

      Click image to see an enlarged view
      Fig. Identifying the cylinder head bolt tightening sequence
  4. Install the 3 coolant tube assembly bolts. Tighten 89 inch lbs. (10 Nm).
  5. Install 8 new RH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
  6. Install new RH exhaust manifold gaskets, the RH exhaust manifold and 8 new nuts. Tighten in the sequence shown to 177 inch lbs. (20 Nm).

    Click image to see an enlarged view
    Fig. Identifying the RH exhaust manifold nut tightening sequence
LH cylinder head
  1. Tighten the new cylinder head bolts in 5 stages in the sequence shown.
    1. Stage 1: Tighten to 177 inch lbs. (20 Nm).
    2. Stage 2: Tighten to 37 ft. lbs. (50 Nm).
    3. Stage 3: Tighten to 59 ft. lbs. (80 Nm).
    4. Stage 4: Tighten an additional 90°.
    5. Stage 5: Tighten an additional 90°.

      Click image to see an enlarged view
      Fig. Identifying the LH cylinder head bolt tightening sequence
  2. Install 8 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
  3. Install new LH exhaust manifold gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown to 177 inch lbs. (20 Nm).

    Click image to see an enlarged view
    Fig. Identifying the LH exhaust manifold nut tightening sequence
Both cylinder heads

NOTE
Do not compress the ratchet assembly. This will damage the ratchet assembly.


5.4L Engine
  1. Compress each tensioner plunger, using an edge of a vise.
  2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
  3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
  4. Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation. Remove the tensioner from the vise.
  5. If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.
  6. Using the Crankshaft Holding Tool, position the crankshaft.
  7. Install the crankshaft sprocket with the flange facing forward.

    Click image to see an enlarged view
    Fig. Installing the crankshaft sprocket with the flange facing forward
  8. Install the LH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  9. Position the camshaft sprocket timing marks.

    Click image to see an enlarged view
    Fig. Positioning the camshaft sprocket timing marks
  10. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.
  11. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
  12. Install the LH primary timing chain tensioner arm.
  13. Install the LH primary timing chain tensioner and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm). Remove the pin from the tensioner.
  14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  15. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.

    Click image to see an enlarged view
    Fig. Positioning the RH timing chain on the crankshaft sprocket
  16. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
  17. Install the RH primary timing chain tensioner arm.
  18. Install the RH primary timing chain tensioner and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm). Remove the pin from the tensioner.
  19. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.

    Click image to see an enlarged view
    Fig. Verifying the alignment of the timing marks on the crankshaft sprocket and the camshaft sprockets
  20. Install the crankshaft washer.
  21. Install the crankshaft sensor ring.
    NOTE
    If the components are to be reinstalled, they must be installed in their original positions or damage to the engine may occur.
  22. Install the hydraulic lash adjusters.

    Click image to see an enlarged view
    Fig. Installing the hydraulic lash adjusters
  23. Using the Valve Spring Compressor, compress the valve spring and install the roller follower.
  24. Repeat the previous step to install all the roller followers.
    NOTE
    Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.
  25. Install the 8 spark plugs. Tighten to 13 ft. lbs. (18 Nm).
    NOTE
    If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 result in future oil leakage.
  26. Apply silicone gasket and sealant in the locations shown.

    Click image to see an enlarged view
    Fig. Identifying silicone gasket and sealant locations
  27. Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:
    1. Bolts 1 through 14 to 18 ft. lbs. (25 Nm).
    2. Bolts 15 and 16 to 37 ft. lbs. (50 Nm).

      Click image to see an enlarged view
      Fig. Identifying the front cover bolt tightening sequence
  28. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
  29. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.
    NOTE
    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  30. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  31. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
  32. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
  33. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
    1. Stage 1: Tighten to 66 ft. lbs. (90 Nm).
    2. Stage 2: Loosen one full turn.
    3. Stage 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Stage 4: Tighten an additional 90°.
  34. Install the coolant pump and the 4 bolts. Tighten to 18 ft. lbs. (25 Nm).
  35. Install the Camshaft Position (CMP) sensor and the bolt. Tighten to 89 inch lbs. (10 Nm).
  36. Install the Crankshaft Position (CKP) sensor and the bolt. Tighten to 89 inch lbs. (10 Nm).
  37. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.
    NOTE
    If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
  38. Apply silicone gasket sealant in the locations shown.
    NOTE
    If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.



    Click image to see an enlarged view
    Fig. Applying silicone gasket sealant
  39. Install the valve covers and the bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the valve cover bolt tightening sequence (LH shown, RH similar)
  40. If equipped, install the LH and RH block drain plugs. Tighten to 124 inch lbs. (14 Nm).
  41. Install the RH engine insulator bracket, the stud bolt, and the 3 bolts. Tighten to 59 ft. lbs. (80 Nm).
    NOTE
    Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.
  42. Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
  43. Using a new gasket, install the oil filter adapter and the 8 bolts. Tighten in the sequence shown. Bolts 1 through 6 to 18 ft. lbs. (25 Nm). Bolts 7 and 8 to 37 ft. lbs. (50 Nm).

    Click image to see an enlarged view
    Fig. Identifying the oil cooler bolt tightening sequence
  44. Install the 3 coolant tube assembly bolts. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.


    NOTE
    Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
  45. Using new intake manifold gaskets, install the intake manifold and the 14 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the intake manifold bolt tightening sequence
  46. Connect the intake manifold-to-coolant tube assembly hose.
  47. Position the wiring harness assembly onto the engine.
    NOTE
    Apply a light film of brake dielectric grease to the inside of the coil boots before installation.
  48. Install the 4 LH coil-on-plugs. Connect the 4 LH coil-on-plug electrical connectors.
  49. Install the LH coil-on-plug cover and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  50. Attach the wiring harness retainers to the LH valve cover stud bolts.
  51. Install the LH radio interference capacitor and the nut. Tighten to 89 inch lbs. (10 Nm).
  52. Connect the 4 LH fuel injector electrical connectors.
  53. Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
  54. Connect the CMP sensor electrical connector.
  55. Connect the Engine Oil Pressure (EOP) switch electrical connector.
    NOTE
    Apply a light film of brake dielectric grease to the inside of the coil boots before installation.
  56. Install the 4 RH coil-on-plugs. Connect the 4 RH coil-on-plug electrical connectors.
  57. Install the RH coil-on-plug cover, bolt and stud bolt. Tighten to 89 inch lbs. (10 Nm).
  58. Install the A/C tube support bracket and nut. Tighten to 80 inch lbs. (9 Nm).
  59. Attach the wiring harness retainers to the RH valve cover stud bolts.
  60. Connect the EGR valve electrical connector.
  61. Install the RH radio interference capacitor and the nut. Tighten to 89 inch lbs. (10 Nm).
  62. Connect the fuel rail pressure and temperature sensor electrical connector.
  63. Connect the 4 RH fuel injector electrical connectors.
  64. Connect the PCV valve electrical connector.
  65. Attach the 2 wiring harness pin-type retainers.
  66. Install the wiring harness retaining bracket and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  67. Connect the bubbler tube from the Supercharger (SC).
  68. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.
  69. Attach the 2 wiring harness pin-type retainers (1 shown) to the coolant tube assembly bracket.
  70. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
  71. Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
  72. Connect the TB control electrical connector.
  73. Connect the TP sensor electrical connector.
  74. Install and connect the crankcase ventilation tube.
  75. Install the EGR tube. Tighten to 30 ft. lbs. (40 Nm).
  76. Install the 3 SC drive belt idler pulleys and the 3 bolts.
    1. Tighten the heavy load idler pulley (closest to centerline of engine) to 35 ft. lbs. (48 Nm).
    2. Tighten the smooth idler pulley and the grooved idler pulley to 18 ft. lbs. (25 Nm).
  77. Install the coolant pump pulley and the 4 bolts. Do not tighten the bolts at this time.
  78. Install the accessory drive belt idler pulley (grooved) and the bolt. Tighten to 18 ft. lbs. (25 Nm).
  79. Install the accessory drive belt idler pulley (smooth) and the stud bolt. Tighten to 18 ft. lbs. (25 Nm).
  80. Install the accessory drive belt tensioner and the bolt. Tighten to 18 ft. lbs. (25 Nm).
  81. Install the alternator, 2 bolts and the stud bolt. Tighten to 37 ft. lbs. (50 Nm).
  82. Connect the generator electrical connector.
  83. Install the power steering pump and reservoir assembly and the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
  84. Install the power steering reservoir bracket bolts. Tighten to 18 ft. lbs. (25 Nm).
  85. Install the power steering tube bracket bolt. Tighten to 89 inch lbs (10 Nm).
  86. Install the power steering tube bracket nut. Tighten to 89 inch lbs. (10 Nm).
  87. Position the SC drive belt and install the SC drive belt tensioner and bolt. Tighten to 35 ft. lbs. (48 Nm).
  88. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
  89. Tighten the 4 coolant pump pulley bolts to 18 ft. lbs. (25 Nm).
  90. Connect the coolant hose from the Charge Air Cooler (CAC).
  91. Install the thermostat housing assembly and the 2 nuts. Tighten to 18 ft. lbs. (25 Nm).
  92. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
  93. Connect the 2 upper radiator hoses to the intake manifold.
  94. Connect the 2 upper radiator hoses to the intake manifold.
  95. Install the coolant tube bracket nut.
  96. Connect the coolant hose to the thermostat housing.
  97. Install the Engine Lifting Bracket.
  98. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.
  99. Install the engine/transmission spacer plate.
  100. Install the flywheel and the 8 bolts. Tighten to 59 ft. lbs. (80 Nm).
  101. Install the engine into the vehicle.




These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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