Thursday, March 15, 2012

Ford Fusion and Mercury Milan Engine replacing procedure?

The details to replace engine.
WITHOUT AUTOMATIC TRANSAXLE:--

With Manual Transaxle
Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009
  1. Raise and safely support the vehicle.
  2. Release the fuel system pressure, as outlined in the Fuel Section.
  3. Disconnect the negative battery cable.
  4. Recover the air conditioning system.
  5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
  6. Remove the 2 nuts and the steering joint cover.
    WARNING
    Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Refer to the Chassis Electrical Section for more information.


    NOTE
    Matchmark the installed position of the steering column shaft to the steering gear for reference during installation.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
  8. Remove the bolt and disconnect the Power Steering Pressure (PSP) tube from the power steering pump.
  9. Route the PSP tube out the bottom of the engine compartment.
  10. Drain the cooling system.
  11. If equipped, remove the 7 screws and the underbody cover.
  12. Remove the exhaust flexible pipe.
    WARNING
    The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
  13. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  14. Remove the engine roll restrictor bolt.
  15. Remove the 4 screws and position the RH fender splash shield aside.
  16. Remove the 6 pin-type retainers and the RH splash shield.
  17. Remove the 4 screws and position the LH fender splash shield aside.
  18. Remove the 6 pin-type retainers and the LH splash shield.
  19. Remove the cotter pins and nuts from the tie-rod ends.
  20. Using the special tool, separate the tie-rod ends from the steering knuckles.
  21. Disconnect the power steering cooler tube.
  22. Remove the nuts and separate the sway bar links from the struts.
  23. Remove the lower ball joint nuts.
    WARNING
    When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.


    NOTE
    Once pressure is applied to the ball joint with the special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
  24. Using the special tools, separate the lower ball joints from the lower control arms.

    Click image to see an enlarged view
    Fig. Using the special tools, separate the lower ball joints from the lower control arms
  25. Remove the through bolts from the lower control arms.
  26. Position the special tool under the subframe assembly.

    Click image to see an enlarged view
    Fig. Position the special tool under the subframe assembly
  27. Remove the subframe bracket-to-body bolts.
  28. Remove the rear subframe nuts and the subframe brackets.
  29. Remove the front subframe nuts.
  30. Lower the subframe assembly from the vehicle.
  31. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 19 ft. lbs. (26 Nm).
  32. Remove the oil filter element.
  33. Remove the bolt, 2 nuts and the generator air inlet duct.
  34. Remove the engine air cleaner and air cleaner outlet pipe.
  35. Remove the battery tray.
  36. Remove the nut and disconnect the wire from the battery cable.
  37. Disconnect the 2 engine wiring harness electrical connectors.
  38. Remove the bolt and the ground wire.
  39. Disconnect the Powertrain Control Module (PCM) electrical connector and pin-type retainer.
  40. Disconnect the fuel supply tube from the fuel rail.
  41. Disconnect the crankcase vent tube from the valve cover.
  42. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
  43. Disconnect the Evaporative emissions (EVAP) tube from the intake manifold.
  44. Detach the retaining clip and position the EVAP tube bundle aside.
  45. Disconnect the upper radiator and heater hoses from the coolant bypass.
  46. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
  47. Disconnect the heater hose inline connector.
  48. Remove the 2 clutch tube bracket bolts.
  49. Remove the 2 bolts and position the clutch slave cylinder aside.
  50. Disconnect the transaxle control cables from the control levers.
  51. Detach the control cables from the bracket.
  52. Disconnect the power steering cooler tube.
  53. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
  54. Detach the coolant vent hose retaining clip from the A/C tube.
  55. Remove the 2 A/C tube bracket bolts.
  56. Remove the 2 nuts and disconnect the A/C tubes.
  57. Remove the nut and disconnect the A/C tube from the condenser.
  58. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
  59. Remove the retaining clip and disconnect the lower radiator hose.
  60. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.

    Click image to see an enlarged view
    Fig. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire
  61. Remove the 2 RH halfshaft carrier bearing bracket bolts.
  62. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
  63. Remove the bellhousing-to-oil pan bolt.
  64. Remove the 2 oil pan-to-bellhousing bolts.
    NOTE
    Position a suitable block of wood under the transaxle.
  65. Install the special tools onto the engine.
  66. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.

    Click image to see an enlarged view
    Fig. Install the special tools onto the engine, then raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts
  67. Remove the 2 transaxle mount bolts.
  68. Remove the bolt, 2 nuts and the motor mount bracket.
  69. Lower the engine and transaxle from the vehicle.
  70. Remove the 2 nuts and disconnect the starter wires.
  71. Detach the 2 wiring harness retainers from the starter stud bolts.
  72. Remove the 2 bolts and the starter.
  73. Remove the bolt and ground wire.
  74. Remove the nut and position the engine wiring harness bracket aside.
  75. Disconnect the backup lamp electrical connector.
  76. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
  77. Install the special tools and remove the engine and transaxle from the powertrain lift table.

    Click image to see an enlarged view
    Fig. Install the special tools and remove the engine and transaxle from the powertrain lift table
  78. Remove the bellhousing-to-engine retainers.
  79. Separate the engine and transaxle
To install:

CAUTION
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the transaxle-to-engine bolts. Tighten to 35 ft. lbs. (48 Nm).
  2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    NOTE
    Position a suitable block of wood under the transaxle.
  3. Install the special tools onto the engine.
  4. Connect the VSS electrical connector.
  5. Connect the backup lamp electrical connector.
  6. Install the engine wiring harness bracket and nut. Tighten to 15 ft. lbs. (20 Nm).
  7. Install the ground wire and bolt. Tighten to 89 inch lbs. (10 Nm).
  8. Install the starter and the 2 stud bolts. Tighten to 18 ft. lbs. (25 Nm).
  9. Connect the starter wires and install the 2 nuts:
    1. Tighten the large nut to 9 ft. lbs. (12 Nm).
    2. Tighten the small nut to 44 inch lbs. (5 Nm).
  10. Attach the 2 wiring harness retainers to the starter stud bolts.
  11. Raise the engine and transaxle into the vehicle.
  12. Install the 2 transaxle mount bolts. Tighten to 66 ft. lbs. (90 Nm).
  13. Install the engine mount bracket, 2 nuts and the bolt:
    1. Tighten the nuts to 76 ft. lbs. (103 Nm).
    2. Tighten the bolt to 85 ft. lbs. (115 Nm).
  14. Install the 2 oil pan-to-bellhousing bolts. Tighten to 35 ft. lbs. (48 Nm).
  15. Install the bellhousing-to-oil pan bolt. Tighten to 35 ft. lbs. (48 Nm).
  16. Install the RH halfshaft into the transaxle.
  17. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 30 ft. lbs. (40 Nm).
    NOTE
    Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from over expanding.
  18. Install a new circlip in the groove on the LH halfshaft.
  19. Install LH halfshaft into the transaxle.
  20. Connect the lower radiator hose and install the retaining clip.
  21. Install the radio frequency interference capacitor and the bolt on the engine mount bracket. Tighten to 89 inch lbs. (10 Nm).
  22. Connect the A/C tube to the condenser and install the nut. Tighten to 71 inch lbs. (8 Nm).
  23. Connect the A/C tubes and install the 2 nuts. Tighten to 71 inch lbs. (8 Nm).
  24. Install the 2 A/C tube bracket bolts. Tighten to 89 inch lbs. (10 Nm).
  25. Attach the coolant vent hose retaining clip to the A/C tube.
  26. Install the radio frequency interference capacitor, ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm).
  27. Connect the power steering cooler tube.
  28. Attach the transaxle control cables to the bracket. Connect the control cables to the control levers.
  29. Install the clutch slave cylinder and the 2 bolts. Tighten to 16 ft. lbs. (22 Nm).
  30. Install the 2 clutch tube bracket bolts. Tighten to 16 ft. lbs. (22 Nm).
  31. Connect the heater hose inline connector.
  32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
  33. Connect the upper radiator and heater hoses to the coolant bypass.
  34. Attach the EVAP tube bundle retaining clip to the bracket.
  35. Connect the EVAP tube to the intake manifold.
  36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
  37. Connect the crankcase vent tube to the valve cover.
  38. Connect the fuel supply tube to the fuel rail.
  39. Connect the PCM electrical connector and the pin-type retainer.
  40. Install the ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm).
  41. Connect the 2 engine wiring harness electrical connectors.
  42. Connect the wire and install the nut on the battery cable. Tighten to 89 inch lbs. (10 Nm).
  43. Install the battery tray.
  44. Install the engine air cleaner and air cleaner outlet pipe.
  45. Install the generator air inlet duct, bolt and the 2 nuts. Tighten to 53 inch lbs. (6 Nm).
  46. Place the subframe assembly on the special tool and raise the subframe into the installed position.
  47. Install the front subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  48. Position the subframe brackets and install the bolts finger-tight.
  49. Install the subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  50. Tighten the subframe bracket-to-body bolts to 76 ft. lbs. (103 Nm).
  51. Install the through bolts into the lower control arms. Tighten to 76 ft. lbs. (103 Nm).
  52. Install the lower ball joint nuts. Tighten to 148 ft. lbs. (200 Nm).
  53. Install the sway bar links and nuts to the struts. Tighten to 30 ft. lbs. (40 Nm).
  54. Connect the power steering cooler tube.
  55. Install tie-rod ends and nuts. Tighten to 35 ft. lbs. (48 Nm). Install the cotter pin.
  56. Install the LH splash shield and the 6 pin-type retainers (4 shown).
  57. Position the LH fender splash shield and install the 4 screws.
  58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
  59. Position the RH fender splash shield and install the 4 screws.
  60. Install the engine roll restrictor bolt. Tighten to 66 ft. lbs. (90 Nm).
  61. Route the PSP tube up into the engine compartment.
  62. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
  63. From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the dash.
  64. Install the oil filter element.
  65. Install the exhaust flexible pipe.
  66. If equipped, install the underbody cover and the 7 screws.
  67. Connect the PSP tube to the power steering pump and install the bolt. Tighten to 26 ft. lbs. (35 Nm).
    NOTE
    Align the matchmarks made during removal.
  68. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 17 ft. lbs. (23 Nm).
  69. Install the steering joint cover and the 2 nuts.
  70. Fill the engine with clean engine oil.
  71. Connect the battery ground cable.
  72. Fill and bleed the cooling system.
  73. Fill the power steering system.
  74. Recharge the air conditioning system
3.0L Engine

CAUTION
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Release the fuel system pressure.
  3. Disconnect the battery ground cable.
  4. Recover the air conditioning system.
  5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
  6. Remove the 2 nuts and the steering joint cover.
    WARNING
    Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.


    NOTE
    Matchmark the installed position of the steering column shaft position to the steering gear for reference during installation.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
  8. Drain the cooling system.
  9. Remove the 4 screws and position the RH fender splash shield aside.
  10. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
  11. Remove the 4 screws and position the LH fender splash shield aside.
  12. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
  13. Disconnect the power steering hose and drain the power steering fluid into a suitable drain pan.
  14. Remove the exhaust flexible pipe.
  15. For All wheel drive (AWD) vehicles:
    NOTE
    Matchmark the driveshaft for installation.

    1. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
      WARNING
      The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
  16. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  17. Remove the Power Steering Pressure (PSP) hose bracket bolt.
  18. Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.
  19. If equipped, remove the 2 bolts and the heat shield.
  20. Remove the 2 bolts and the engine roll restrictor.
  21. Remove the cotter pins and nuts from the tie-rod ends.
  22. Using the a suitable tie-rod end removal tool, separate the tie-rod ends from the steering knuckles.
  23. Remove the nuts and separate the stabilizer bar links from the struts.
  24. Remove the lower ball joint nuts.
    WARNING
    When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.


    NOTE
    Once pressure is applied to the ball joint with the special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
  25. Using the special tools, separate the lower ball joints from the lower control arms.

    Click image to see an enlarged view
    Fig. Using the special tools, separate the lower ball joints from the lower control arms
  26. Remove the through bolts from the lower control arms.
  27. Position the special tool under the subframe assembly.

    Click image to see an enlarged view
    Fig. Position the special tool under the subframe assembly
  28. Remove the subframe bracket-to-body bolts.
  29. Remove the subframe nuts and the subframe brackets.
  30. Remove the front subframe nuts.
  31. Lower the subframe assembly from the vehicle.
  32. Disconnect the transaxle cooler hoses.
  33. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 19 ft. lbs. (26 Nm).
  34. Remove and discard the engine oil filter.
  35. Remove the engine air cleaner and air cleaner outlet pipe.
  36. Remove the battery tray.
  37. Remove the nut and disconnect the power feed wire from the battery terminal.
  38. Disconnect the 2 engine wiring harness electrical connectors.
  39. Remove the bolt and position aside the ground wire.
  40. Disconnect the Powertrain Control Module (PCM) electrical connector and the pin-type retainer.
  41. Disconnect the fuel supply tube from the fuel rail.
  42. Disconnect the heater hose from the thermostat housing.
  43. Disconnect the heater hose inline connection.
  44. Disconnect the throttle body coolant hose.
  45. Disconnect the Evaporative emissions (EVAP) hose.
  46. Disconnect the upper and lower radiator hoses from the thermostat housing.
  47. Disconnect the transaxle control cable from the transaxle selector lever.
  48. Remove the 3 transaxle control cable bracket bolts and position the cable aside.
  49. Remove the bolt and position the ground wire aside.
  50. Remove the vacuum tube bracket bolt.
  51. Disconnect the vacuum hose from the intake manifold.
  52. If equipped, detach the block heater cable retaining clips from the cooling fan shroud.
  53. Disconnect the power steering hose from the power steering reservoir.
  54. Detach the power steering hose retaining clip from the LH valve cover stud bolt and the engine wiring harness.
  55. Disconnect the coolant hose from the degas bottle.
  56. Detach the coolant hose retaining clip and position the coolant hose aside.
  57. Remove the 2 A/C tube bracket bolts.
  58. Remove the 2 nuts and disconnect the A/C tubes.
  59. Remove the bolt and the ground wire from the engine mount bracket.
  60. Remove the bolt and separate the A/C manifold from the A/C compressor.
  61. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.

    Click image to see an enlarged view
    Fig. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire
  62. For early build Front Wheel Drive (FWD) vehicles:
    1. Disconnect the Crankshaft Position (CKP) sensor electrical connector and pin-type retainer.
    2. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
    3. Disconnect the catalyst monitor sensor electrical connector and pin-type retainer.
  63. For FWD vehicles:
    1. Remove the 2 RH halfshaft carrier bearing bracket bolts.
    2. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
  64. For AWD vehicles:
    1. Disconnect the RH catalyst monitor sensor electrical connector and detach the wiring retainer.
    2. Using the special sensor tool, remove the RH catalyst monitor sensor.
    3. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
    4. Using the special tool, remove the RH HO2S.
    5. Remove the 6 bolts and the RH exhaust heat shield.
    6. Remove the 3 nuts and the RH exhaust heat shield bracket (outboard half).
    7. Remove the 2 bolts and the RH exhaust heat shield bracket (inboard half).
    8. Remove the 3 nuts (2 shown) and the RH catalytic converter.
    9. Discard the nuts and gasket.
    10. Remove the 2 halfshaft carrier bearing bolts.
    11. Separate the RH halfshaft from the power transfer unit (PTU) and support the halfshaft with a length of mechanic's wire.
    12. Remove the 5 bolts and the PTU support bracket
    13. Remove the 5 bolts and the PTU.
  65. Remove the torque converter nut access plug.
  66. Remove the 3 torque converter nuts.
  67. Remove the 2 oil pan-to-transaxle bolts.
    NOTE
    Position a suitable block of wood under the transaxle.
  68. Install the special tools onto the engine.
  69. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.

    Click image to see an enlarged view
    Fig. Install the special tools onto the engine, then raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts
  70. Remove the 2 transaxle mount bolts.
  71. Remove the bolt and damper.
  72. Remove the bolt, 3 nuts and the engine mount bracket.
  73. Lower the engine and transaxle from the vehicle.
  74. Install the special tools.
  75. Detach the wiring harness retainer from the PSP hose bracket.
  76. Remove the bolt and detach the PSP hose bracket from the cylinder head.
  77. Remove the bolt and detach the PSP hose bracket from the cylinder head.
  78. Remove the bolt and detach the PSP hose bracket from the power steering reservoir.
  79. Remove the banjo bolt and the PSP hose. Discard the banjo bolt and 2 seals.
  80. Install the special tool.

    Click image to see an enlarged view
    Fig. Install the special tool
  81. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.
  82. Loosen the EGR tube-to-EGR valve nut.
  83. Remove the 2 bolts and the EGR valve. Discard the gasket.
  84. Loosen the EGR tube-to-catalytic converter nut and remove the EGR tube.
  85. For FWD vehicles:
    1. Remove the 2 bolts and the heat shield.
    2. Remove the 2 bolts and the catalytic converter bracket.
    3. Remove the 2 bolts and the catalytic converter bracket assembly.
      NOTE
      When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
  86. Install the lower half of the special tool.
  87. Install the upper half of the special tool.

    Click image to see an enlarged view
    Fig. Install the lower half of the special tool


    Click image to see an enlarged view
    Fig. Install the upper half of the special tool
  88. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.

    Click image to see an enlarged view
    Fig. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table
  89. Remove the bolt and ground wire.
  90. Remove the bolt and the catalyst monitor sensor electrical connector bracket.
  91. Disconnect the Transmission Control Module (TCM) electrical connector.
  92. Remove the 2 nuts and the starter motor wiring.
  93. Remove the 2 bolts and the starter motor.
  94. Remove the engine-to-transaxle bolt.
  95. Remove the 3 transaxle-to-engine bolts.
  96. Detach the wiring harness retainer from the stud bolt.
  97. Remove the transaxle-to-engine stud bolt, bolt and nut.
  98. Using the special tools and a suitable engine crane, separate the engine and transaxle.

    Click image to see an enlarged view
    Fig. Using the special tools and a suitable engine crane, separate the engine and transaxle
To install:

WARNING
If the oil pan was removed during engine disassembly, it must be installed after engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

  1. Using the special tools and a suitable engine crane, align the transaxle to the engine.
  2. Install the transaxle-to-engine stud bolt, bolt and nut. Tighten to 35 ft. lbs. (48 Nm).
  3. Attach the wiring harness retainer to the stud bolt.
  4. Install the 3 transaxle-to-engine bolts. Tighten to 35 ft. lbs. (48 Nm).
  5. Install the engine-to-transaxle bolt. Tighten to 35 ft. lbs. (48 Nm).
    WARNING
    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.
  6. Use a plastic scraping tool to remove all traces of the oil pan gasket.
  7. Clean all sealing surfaces with metal surface cleaner and install a new oil pan gasket.
    NOTE
    The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
  8. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.

    Click image to see an enlarged view
    Fig. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated
  9. Position the oil pan and install the 10 bolts and 5 stud bolts finger-tight.
  10. Install the 2 oil pan-to-transaxle bolts. Tighten to 35 ft. lbs. (48 Nm).
  11. Tighten the 15 oil pan-to-engine bolts and stud bolts in the sequence shown to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view
    Fig. Oil pan-to-engine retainer tightening sequence-3.0L engine
  12. Install 6 new LH catalytic converter studs. Tighten to 9 ft. lbs. (12 Nm).
  13. Install a new gasket, the LH catalytic converter and 6 new nuts. Tighten to 15 ft. lbs. (20 Nm) in the sequence shown.

    Click image to see an enlarged view
    Fig. Install a new gasket, the LH catalytic converter and 6 new nuts. Tighten to 15 ft. lbs. (20 Nm) in the proper sequence
  14. Install the LH catalytic converter bracket and the 2 bolts. Tighten to 15 ft. lbs. (20 Nm).
  15. Install the heat shield and the 4 bolts. Tighten to 8 ft. lbs. (11 Nm).
  16. Connect the LH heated oxygen sensor (HO2S) electrical connector and pin-type retainer.
  17. Connect the LH catalyst monitor sensor electrical connector.
  18. Install the starter motor and the 2 bolts. Tighten to 20 ft. lbs. (27 Nm).
  19. Connect the starter motor wiring and install the 2 nuts:
    1. Tighten the large nut to 9 ft. lbs. (12 Nm).
    2. Tighten the small nut to 44 inch lbs. (5 Nm).
  20. Connect the Transmission Control Module (TCM) electrical connector.
  21. Install the catalyst monitor sensor bracket and the bolt. Tighten to 9 ft. lbs. (12 Nm).
  22. Install the ground wire and the bolt. Tighten to 9 ft. lbs. (12 Nm).
  23. Using the special tools and a suitable engine crane, position the engine and transaxle onto the lift table.
    NOTE
    Position a suitable block of wood under the transaxle.
  24. Install the special tools.

    Click image to see an enlarged view
    Fig. Install the special tools
  25. For FWD vehicles:
    1. Install the catalytic converter bracket assembly and the 2 bolts. Tighten to 26 ft. lbs. (35 Nm).
    2. Install the catalytic converter bracket and the 2 bolts. Tighten to 15 ft. lbs. (20 Nm).
    3. Install the heat shield and the 2 bolts. Tighten to 8 ft. lbs. (11 Nm).
  26. Using a new gasket, install the EGR valve and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm).
  27. Install the EGR tube. Tighten both EGR tube nuts to 30 ft. lbs. (40 Nm).
  28. Connect the EGR valve electrical connector.
  29. Position the PSP hose on the engine and install the PSP hose bracket-to-power steering reservoir bolt. Tighten to 80 inch lbs. (9 Nm).
  30. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering pump. Tighten to 27 ft. lbs. (37 Nm).
  31. Attach the PSP hose bracket to the cylinder head and install the bolt. Tighten to 80 inch lbs. (9 Nm).
  32. Attach the PSP hose bracket to the cylinder head and install the bolt. Tighten to 80 inch lbs. (9 Nm).
  33. Attach the wiring harness retainer to the PSP hose bracket.
  34. Raise the engine and transaxle up into the vehicle.
  35. Install the engine mount bracket, 3 nuts and the bolt:
    1. Tighten the nuts to 46 ft. lbs. (63 Nm).
    2. Tighten the bolt to 85 ft. lbs. (115 Nm).
  36. Install the damper and bolt. Tighten to 17 ft. lbs. (23 Nm).
  37. Install the 2 transaxle mount bolts. Tighten to 66 ft. lbs. (90 Nm).
  38. Install the 3 torque converter nuts. Tighten to 27 ft. lbs. (36 Nm).
  39. Install the torque converter nut access plug.
  40. For AWD vehicles:
    1. Install the power transfer unit (PTU) and the 5 bolts. Tighten to 66 ft. lbs. (90 Nm).
    2. Install the PTU support bracket and the 5 bolts. Tighten to 52 ft. lbs. (70 Nm).
      WARNING
      A new power transfer unit (PTU) seal must be installed whenever the intermediate shaft is removed.
    3. Install a new PTU seal.
      NOTE
      Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
    4. Position the RH driveshaft in place and install the 2 bolts. Tighten to 17 ft. lbs. (23 Nm).
    5. Using a new gasket, install the RH catalytic converter and 3 new nuts. Tighten to 35 ft. lbs. (48 Nm).
    6. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts. Tighten to 30 ft. lbs. (40 Nm).
    7. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts. Tighten to 15 ft. lbs. (20 Nm).
    8. Install the RH exhaust heat shield and the 6 bolts. Tighten to 8 ft. lbs. (11 Nm).
    9. Using the special tool, install the RH HO2S. Tighten to 35 ft. lbs. (48 Nm).
    10. Connect the RH HO2S electrical connector.
    11. Using the special tool, install the RH catalytic monitor sensor. Tighten to 35 ft. lbs. (48 Nm).
    12. Connect the RH catalyst monitor sensor electrical connector and attach the wiring harness retainer.
  41. For FWD vehicles:
    1. Install the RH halfshaft into the transaxle.
    2. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 41 ft. lbs. (55 Nm).
  42. For Early build FWD vehicles:
    1. Connect the catalyst monitor sensor electrical connector and pin-type retainer.
    2. Connect the PSP switch electrical connector.
    3. Connect the CKP sensor electrical connector and pin-type retainer.
      NOTE
      Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.


      NOTE
      Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from over expanding.
  43. Install a new circlip in the groove on the LH halfshaft.
  44. Install the LH halfshaft into the transaxle.
  45. Position the A/C manifold onto the A/C compressor and install the bolt. Tighten to 11 ft. lbs. (15 Nm).
  46. Install the ground wire and bolt to the engine mount bracket. Tighten to 89 inch lbs. (10 Nm).
  47. Connect the A/C tubes and install the 2 nuts. Tighten to 71 inch lbs. (8 Nm).
  48. Install the 2 A/C tube bracket bolts. Tighten to 89 inch lbs. (10 Nm).
  49. Attach the coolant hose retaining clip.
  50. Connect the coolant hose to the degas bottle.
  51. Attach the power steering hose retaining clip to the engine wiring harness and the LH valve cover stud bolt.
  52. Connect the power steering hose to the power steering reservoir.
  53. If equipped, attach the block heater cable retaining clips to the cooling fan shroud.
  54. Connect the vacuum hose to the intake manifold.
  55. Install the vacuum tube bracket bolt. Tighten to 89 inch lbs. (10 Nm).
  56. Install the ground wire and the bolt. Tighten to 9 ft. lbs. (12 Nm).
  57. Install the transaxle control cable bracket and the 3 bolts. Tighten to 71 inch lbs. (8 Nm).
  58. Connect the transaxle control cable to the transaxle selector lever.
  59. Connect the upper and lower radiator hoses to the thermostat housing.
  60. Connect the EVAP hose.
  61. Connect the throttle body coolant hose.
  62. Connect the heater hose inline connection.
  63. Connect the heater hose to the thermostat housing.
  64. Connect the fuel supply tube to the fuel rail.
  65. Connect the PCM electrical connector and the pin-type retainer.
  66. Install the ground wire and bolt. Tighten to 89 inch lbs. (10 Nm).
  67. Connect the 2 engine wiring harness electrical connectors.
  68. Connect the power feed to the battery terminal and install the nut. Tighten to 53 inch lbs. (6 Nm).
  69. Install the battery tray.
  70. Install the engine air cleaner and air cleaner outlet pipe.
    NOTE
    Lubricate the engine oil filter gasket with clean engine oil prior to installing.
  71. Install a new engine oil filter. Tighten to 44 inch lbs. (5 Nm) and then rotate an additional 180 degrees.
  72. Connect the transaxle cooler hoses.
  73. Place the subframe assembly on the special tool and raise the subframe into the installed position.
  74. Install the front subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  75. Position the subframe brackets and install the bolts finger-tight.
  76. Install the subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  77. Tighten the subframe bracket-to-body bolts to 76 ft. lbs. (103 Nm).
  78. Install the through bolts into the lower control arms. Tighten to 76 ft. lbs. (103 Nm).
  79. Install the lower ball joint nuts. Tighten to 148 ft. lbs. (200 Nm).
  80. Install the sway bar links and nuts to the struts. Tighten to 30 ft. lbs. (40 Nm).
  81. Connect the power steering cooler hose.
  82. Install the tie-rod ends and nuts. Tighten to 35 ft. lbs. (48 Nm). Install the cotter pin.
  83. Install the LH splash shield and the 6 pin-type retainers (4 shown).
  84. Position the LH fender splash shield and install the 4 screws.
  85. Install the RH splash shield and the 6 pin-type retainers (4 shown).
  86. Position the RH fender splash shield and install the 4 screws.
  87. Install the engine roll restrictor and the 2 bolts. Tighten to 66 ft. lbs. (90 Nm).
  88. If equipped, install the heat shield and the 2 bolts.
  89. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering gear. Tighten to 27 ft. lbs. (37 Nm).
  90. Position the PSP hose onto the steering gear and install the PSP hose bracket bolt. Tighten to 11 ft. lbs. (15 Nm).
  91. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
  92. From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the body.
  93. For AWD vehicles:
    1. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown).
    2. Tighten to 52 ft. lbs. (70 Nm).
  94. Install the exhaust flexible pipe.
    NOTE
    Align the index marks made during removal.
  95. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 17 ft. lbs. (23 Nm).
  96. Install the steering joint cover and the 2 nuts.
  97. Fill the engine with clean engine oil.
  98. Connect the battery ground cable.
  99. Fill and bleed the cooling system.
  100. Fill the power steering system.
  101. Check the transaxle fluid and add fluid if necessary.
  102. Recharge the air conditioning system



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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