Engine Mechanical - 1.4L (Luv): Removal & Installation Chevrolet Sonic I

Removal Procedure

1. Disconnect the oil pressure indicator switch wiring harness plug.
2. Remove the oil pressure indicator switch (1) and the oil pressure indicator switch seal ring (2).

Installation Procedure

1. Install the oil pressure indicator switch (1) and a NEW oil pressure indicator switch seal ring (2).
2. Tighten the oil pressure indicator switch to 20 N.m (15 lb ft).

1. Remove the throttle body assembly. Refer to «Throttle Body Assembly Replacement»(ref-542528-S34938080062013041600000) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-542528-S37844328162013041600000) .
3. Remove the relay holder cover.
4. Remove the fuel pump relay.
5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the cylinders.
6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking speed is below 300 RPM, repair the slow cranking speed condition before continuing with the compression test.
7. Install EN-48248 gauge in the spark plug bore for the cylinder that is being checked.
8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the cylinder being tested.
9. Observe the compression gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level.
10. Record the compression reading for the cylinder just tested.
11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings.
12. The maximum pressure differential should not exceed 100 kPa (14.5 psi).
13. The nominal cylinder compression value is for natural aspirated engines 1300 kPa - 1500 kPa (188.5 psi - 217.6 psi). for turbo engines 1200 kPa - 1400 kPa (174 psi - 203.1 psi).

1. Install the fuel pump relay.
2. Install the relay holder cover.
3. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-542528-S37844328162013041600000) .
4. Install the throttle body assembly. Refer to «Throttle Body Assembly Replacement»(ref-542528-S34938080062013041600000) .

1. Remove the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
3. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
4. Install EN-48488 holding wrench (2) to the drive belt tensioner (1).
5. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955 locking pin (1).
6. Remove the EN-48488 holding wrench.
7. Remove the drive belt (1).

1. Install the drive belt (1).
2. Install the EN-48488 holding wrench (2) to the drive belt tensioner (1).
3. Move the drive belt tensioner clockwise until EN-955 locking pin (1) can be removed.
4. Allow the tensioner to slide back slowly.
5. Remove the EN-48488 holding wrench.
6. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
7. Install the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
8. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .

1. Remove the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) and «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
3. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
4. Install the EN-48488 holding wrench (2) to the drive belt tensioner (1).
5. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955 locking pin (1).
6. Remove the EN-48488 holding wrench.
7. Remove the drive belt.
8. Repeat steps 4 and 5 in order to remove the EN-955 locking pin from the drive belt tensioner.
9. Remove the lower drive belt tensioner bolt (1).
10. Remove the upper drive belt tensioner bolt (2).
11. Remove the drive belt tensioner (3).

1. Install the drive belt tensioner (3).
2. Install the lower drive belt tensioner bolt (1).
3. Install the upper drive belt tensioner bolt (2).
4. Tighten the lower drive belt tensioner bolt (1) to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt (2) to 55 N.m (41 lb ft).
6. Install the EN-48488 holding wrench (2) to drive belt tensioner (1).
7. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955 locking pin (1).
8. Install the drive belt.
9. Move the drive belt tensioner clockwise until EN-955 locking pin can be removed.
10. Allow the tensioner to slide back slowly.
11. Remove the EN-48488 holding wrench.
12. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
13. Install the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) and «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
14. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .

Scheme 51

Engine Mount Replacement - Right Side

Scheme 52

Engine Mount Bracket Replacement - Right Side

Scheme 53

Engine Cover Replacement

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
2. Remove the engine sight shield.
3. Unclip the heater outlet hose from retainer clip (1).
4. Unclip the engine control module wiring harness from 2 retainer clips (2).
5. Lower the vehicle.
6. Remove the charge air cooler outlet air hose from the throttle body. Refer to «Charge Air Cooler Outlet Air Hose Replacement»(ref-542528-S31233294992013041600000) .
7. Disconnect the throttle body wiring harness plug (1).
8. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
9. Disconnect the manifold absolute pressure sensor wiring harness plug (1).
10. Disconnect the 4 fuel injector wiring harness plugs (4).
11. Unclip the engine control module wiring harness from the camshaft cover.
12. Disconnect the PCV hose (3).
13. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
14. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).
15. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-542528-S11751073572013041600000) .
16. Remove the fuel feed pipe (4) from fuel injector rail.
17. Unclip the fuel feed pipe from retainer clip (1).
18. Remove the fuel ventilation pipe (2) from evaporative emission canister purge solenoid valve.
19. Unclip the fuel ventilation pipe from retainer clip (1).
20. Close the vents with the EN-6015 closure plugs.
21. Disconnect the brake booster vacuum pipe (3) from the intake manifold.
22. Remove the 6 intake manifold bolts (1).
23. Remove the intake manifold (1) and the intake manifold gasket.
24. Transfer parts from intake manifold as necessary. Refer to «Intake Manifold Disassemble»(ref-542544-S02562656832013041600000) , and «Intake Manifold Assemble»(ref-542544-S38998809092013041600000) .

1. Clean the sealing surfaces.
2. Install the intake manifold (1) along with a NEW intake manifold gasket.
3. Install the 6 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).
4. Connect the fuel ventilation pipe (2) to the evaporative emission canister purge solenoid valve.
5. Clip in the fuel ventilation pipe to the retainer clip (1).
6. Connect the fuel feed pipe (4) to the injector rail.
7. Clip in the fuel feed pipe to the retainer clip (1).
8. Connect the brake booster vacuum pipe (3) to the intake manifold.
9. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
10. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).
11. Clip in the engine control module wiring harness to the camshaft cover.
12. Connect the 4 fuel injector wiring harness plugs (4).
13. Connect the manifold absolute pressure sensor wiring harness plug (1) .
14. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
15. Connect the PCV hose (3).
16. Connect the throttle body wiring harness plug (1).
17. Install the charge air cooler outlet air hose to the throttle body. Refer to «Charge Air Cooler Outlet Air Hose Replacement»(ref-542528-S31233294992013041600000) .
18. Raise and support the vehicle.
19. Clip in the heater outlet hose to retainer clip (1).
20. Clip in the engine control module wiring harness to 2 retainer clips (2).
21. Install the engine sight shield.
22. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .

1. Remove the engine front cover. Refer to «Engine Front Cover with Oil Pump Replacement»(ref-542544-S15979241822013041600000) .
2. Push the timing chain (2) in direction to the timing chain tensioner (1) and install the EN-955 pin (3).
3. Remove the two upper timing chain guide bolts (1).
4. Remove the upper timing chain guide (2).
5. Remove the two timing chain guide right side bolts (2).
6. Remove the timing chain guide right side (1).
7. Remove the timing chain tensioner shoe bolt (2).
8. Remove the timing chain tensioner shoe (1).
9. Remove the timing chain (1) and crankshaft sprocket (2) together as a unit.
10. Remove the engine front cover gasket (1).

1. Clean the engine front cover sealing surfaces on engine block and cylinder head.
2. Apply a 2 mm (0.0787 in) bead of RTV sealant the areas shown above (1, 2).
3. Install the engine front cover gasket (1).
4. Install the two upper timing chain guide bolts (1) and tighten to 8 N•m (71 lb in).
5. Install the upper timing chain guide (2).
6. Install the timing chain (1) and crankshaft sprocket (2) together as a unit.
7. Install the timing chain tensioner shoe (1).
8. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).
9. Install the timing chain guide right side (1).
10. Install the timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).
11. Push the timing chain (2) in direction of the timing chain tensioner (1) and remove EN-955 pin (3).
12. Install the engine front cover. Refer to «Engine Front Cover with Oil Pump Replacement»(ref-542544-S15979241822013041600000) .

Scheme 54

Timing Chain Tensioner Replacement

Scheme 55

Hydraulic Valve Lash Adjuster Arm Replacement

Scheme 56

Hydraulic Valve Lash Adjuster Replacement

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-542528-S25099370852013041600000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-542544-S24703244862013041600000) .
3. Remove both camshaft position actuator solenoid valves. Refer to «Camshaft Position Actuator Solenoid Valve Replacement»(ref-542528-S02046342552013041600000) .
4. Adjust the engine to TDC. Refer to «Camshaft Timing Chain Adjustment»(ref-542544-S21827986062013041600000) .
5. Remove the timing chain tensioner plug (1) from the engine front cover.
6. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the exhaust camshaft in order to apply tension.
7. Install EN-955 pin (2) to the timing chain tensioner bore (1) to secure it in place.
8. Remove the wrench from intake camshaft.
9. Remove the upper timing chain guide bolts (1).
10. Remove the upper timing chain guide (2).
11. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a wrench (1).
12. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a wrench.
13. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).
14. Remove the camshaft sprockets (2) and timing chain (1) as one unit.
15. Remove the intake and exhaust camshaft sprocket.
16. Allow the chain to rest on the front cover.

1. Install the camshaft sprockets (2) and timing chain (1) as one unit.
2. Install the camshaft position exciter wheels (1).
3. Install the NEW camshaft sprocket bolts (2) and tighten to 50 N.m (37 lb ft) plus 60 degrees.
4. Remove the EN-955 pin to apply tension to the timing chain .
5. Adjust the camshaft timing chain. Refer to «Camshaft Timing Chain Adjustment»(ref-542544-S21827986062013041600000) .
6. Install the upper timing chain guide (2).
7. Install the upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
8. Install the timing chain tensioner plug (1) and tighten to 50 N.m (37 lb ft).
9. Install both camshaft position actuator solenoid valves. Refer to «Camshaft Position Actuator Solenoid Valve Replacement»(ref-542528-S02046342552013041600000) .
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-542544-S24703244862013041600000) .
11. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-542528-S25099370852013041600000) .
12. Check and correct engine oil level.

1. Disconnect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
2. Remove the exhaust manifold and turbocharger as an assembly. Refer to «Turbocharger Replacement»(ref-542544-S16601291452013041600000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-542544-S05907954652013041600000) .
4. Remove the water outlet. Refer to «Water Outlet Replacement (LUV)»(ref-542500-S04232243022013041600000) .
5. Remove the camshaft position actuator solenoid valve intake and exhaust. Refer to «Camshaft Position Actuator Solenoid Valve Replacement»(ref-542528-S02046342552013041600000) .
6. Adjust the engine to TDC. Refer to «Camshaft Timing Chain Inspection»(ref-542544-S34513644892013041600000) .
7. Remove the timing chain tensioner plug (1) from the engine front cover.
8. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the exhaust camshaft in order to apply tension.
9. Install EN-955-10 pin (2) to the timing chain tensioner bore (1) to secure it in place.
10. Remove the wrench from intake camshaft.
11. Remove the upper timing chain guide bolts (1).
12. Remove the upper timing chain guide (2).
13. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a wrench (1).
14. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a wrench.
15. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).
16. Remove the both camshaft position sensors. Refer to «Camshaft Position Sensor Replacement»(ref-542528-S39614631702013041600000) .
17. Remove the camshaft sprockets (2) and timing chain (1) as one unit.
18. Allow the camshaft sprockets (2) and timing chain (1) rest on the front cover. Do NOT remove sprockets or chain.
19. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
20. Remove the engine mount bracket. Refer «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
21. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
22. Remove the water pump pulley. Refer to «Water Pump Pulley Replacement (LUV)»(ref-542500-S33570717302013041600000) .
23. Remove 5 engine front cover bolts (1, 2).
24. Remove 3 water pump bolts (3).
25. Install engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
26. Install engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-542544-S41377953382013041600000) .
27. Remove engine support fixture. Refer «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
28. Loosen the 12 cylinder head bolts in the sequence as shown above. Use the following procedure: First pass: Loosen the cylinder head bolts 90 degrees. Final pass: Loosen the cylinder head bolts 180 degrees.
29. Remove and DISCARD the 12 cylinder head bolts (1).
30. With the aid of an assistant, lift the timing chain side of the cylinder head assembly slightly in direction of the transmission.
31. Remove the cylinder head (2).
32. Remove the cylinder head gasket (3) and discard the gasket.
33. With the cylinder head out of vehicle, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.
34. Remove the assembly parts from cylinder head: Remove the EN-953-A fixing tool Remove the intake camshaft. Refer to «Intake Camshaft Removal»(ref-542544-S01395633952013041600000) . Remove the exhaust camshaft. Refer to «Exhaust Camshaft Removal»(ref-542544-S37188444972013041600000) . Remove the hydraulic valve lash adjuster arms. Refer to «Hydraulic Valve Lash Adjuster Arm Removal»(ref-542544-S22687820132013041600000) . Remove the hydraulic valve lash adjusters. Refer to «Hydraulic Valve Lash Adjuster Removal»(ref-542544-S35951228142013041600000) . Remove the spark plug. Refer to «Spark Plug Replacement»(ref-542528-S37844328162013041600000) . Remove the engine oil pressure indicator switch. Remove the timing chain tensioner. Refer to «Timing Chain Tensioner Removal»(ref-542544-S08593530452013041600000) . Remove the 3 engine lift brackets.
35. For disassembly of the cylinder head. Refer to «Cylinder Head Disassemble»(ref-542544-S24265966362013041600000) .
36. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-542544-S17087440512013041600000) .
37. Transfer parts as necessary.

1. For assembly of the cylinder head. Refer to «Cylinder Head Assemble»(ref-542544-S08330716402013041600000) .
2. Install the cylinder head assembly parts: Install the 3 engine lift bracket bolts and tighten to22 (16 lb ft). Install the timing chain tensioner. Refer to «Timing Chain Tensioner Installation»(ref-542544-S39324971132013041600000) . Install the engine oil pressure indicator switch and tighten to 20 (15 lb ft) Install the spark plug. Refer to «Spark Plug Replacement»(ref-542528-S37844328162013041600000) . Install the hydraulic valve lash adjusters. Refer to «Hydraulic Valve Lash Adjuster Installation»(ref-542544-S02040314942013041600000) . Install the hydraulic valve lash adjuster arms. Refer to «Hydraulic Valve Lash Adjuster Arm Installation»(ref-542544-S42553129852013041600000) . Install the exhaust camshaft. Refer to «Exhaust Camshaft Installation»(ref-542544-S01759324822013041600000) . Install the intake camshaft. Refer to «Intake Camshaft Installation»(ref-542544-S00798440562013041600000) . Install the EN-953-A fixing tool.
3. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.
4. Before installation the of the new front cover gasket, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.
5. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (1).
6. Install a NEW cylinder head gasket. The marking "Top" should point to the cylinder head.
7. Install engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.
8. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (2).
9. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the installed fixing pin through the timing chain tensioner plug bore in engine front cover.
10. Install the cylinder head (2).
11. Loosely install 12 NEW cylinder head bolts (1).
12. Adjust the cylinder head to the engine front cover. Use a rubber mallet.
13. Position the engine front cover to cylinder head by installing 3 bolts (1).
14. Tighten the 3 bolts (1) to 8 (71 lb in).
15. Tighten the cylinder head bolts in the sequence as shown and in the following order. Tighten the cylinder head bolts to 35 (26 lb ft). Tighten the cylinder head bolts an additional 180°. Use EN-470-B wrench.
16. Loosen the bolts from engine front cover (1).
17. Install the remaining bolts to engine front cover and water pump.
18. Tighten the engine front cover bolts (1, 2) to 8 (71 lb in).
19. Tighten the water pump bolts (3) to 8 (71 lb in).
20. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
21. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
22. Install the water pump pulley. Refer to «Water Pump Pulley Replacement (LUV)»(ref-542500-S33570717302013041600000) .
23. Install the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
24. Install engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
25. Install the engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-542544-S41377953382013041600000) .
26. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-542544-S08212220532013041600000) .
27. Install the camshaft sprockets (2) and timing chain (1) as one unit.
28. Install the camshaft position exciter wheels (1).
29. Install the NEW camshaft sprocket bolts (2) and tighten to 50 (37 lb ft) plus 60 degrees.
30. Install the both camshaft position sensors. Refer to «Camshaft Position Sensor Replacement»(ref-542528-S39614631702013041600000) .
31. Remove the EN-955-10 pin to apply tension to the timing chain.
32. Adjust the camshaft timing chain. Refer to «Camshaft Timing Chain Inspection»(ref-542544-S34513644892013041600000) .
33. Install the upper timing chain guide (2).
34. Install the upper timing chain guide bolts (1) and tighten to 8 (71 lb in).
35. Install the timing chain tensioner plug and tighten to 50 (37 lb ft).
36. Install the camshaft position actuator solenoid valve intake and exhaust. Refer to «Camshaft Position Actuator Solenoid Valve Replacement»(ref-542528-S02046342552013041600000) .
37. Install the exhaust manifold and turbocharger as an assembly. Refer to «Turbocharger Replacement»(ref-542544-S16601291452013041600000) .
38. Install the Intake manifold. Refer to «Intake Manifold Replacement»(ref-542544-S05907954652013041600000) .
39. Fill coolant fluid. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
40. Connect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
41. Check and correct the engine oil.
42. Test the vehicle using the following procedure: Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. Start the engine and listen for unusual noises. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. Listen for sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running.
43. Inspect for coolant, oil, gas or exhaust leaks.

1. Remove the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
2. Remove the oil filter and drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-542544-S16162666712013041600000) .
3. Remove the front insulator cover. Refer to «Front Compartment Front Insulator Cover Replacement»(ref-542501-S04169640362013041600000) .
4. Remove the front exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV,LUW)»(ref-542543-S08102879492013041600000) .
5. If equipped with an automatic transmission, remove the oil pan to automatic transmission bolts (1, 3) and automatic transmission converter cover (2).
6. Remove the oil pan to automatic transmission bolts (1) .
7. If equipped with manual transmission, remove the 3 manual transmission to oil pan bolts (1).
8. Remove the oil pan bolts (1) and oil pan.

1. Clean the sealing surface of crankshaft bearing cap tie plate and the groove in the engine front cover from old gasket material, oil, dirt and grease.
2. Install the 2 EN-49980 guidance pins (1) to the shown oil pan screw bores.
3. Apply 2 mm (0.0787 in) thickness of sealing compound (3, 2, 1).
4. Loosely install the oil pan bolts (1) in all but the guidance pin locations.
5. Remove the EN-49980 guidance pins and install the remaining oil pan bolts.
6. Tighten the oil pan bolts to 10 N.m (89 lb in).
7. If equipped with manual transmission, install the 3 manual transmission to oil pan bolts (1) and tighten to 40 N.m (30 lb ft).
8. If equipped with an automatic transmission, install and the automatic transmission converter cover (2) and tighten the cover to automatic transmission bolt (1) to 40 N.m (30 lb ft) and automatic transmission bolt (3) to 60 N.m (44 lb ft).
9. Install the oil pan to automatic transmission bolts (1), and tighten to 40 N.m (30 lb ft).
10. Install a NEW oil filter and fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-542544-S16162666712013041600000) .
11. Install the exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV,LUW)»(ref-542543-S08102879492013041600000) .
12. Install the front insulator cover. Refer to «Front Compartment Front Insulator Cover Replacement»(ref-542501-S04169640362013041600000) .
13. Install the right front wheelhouse liner extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .

Scheme 57

Automatic Transmission Flex Plate Replacement

Scheme 58

Engine Flywheel Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove front wheelhouse liner extension right side. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
4. Place collecting basin underneath.
5. Rotate the engine clockwise until the bore (2) in the crankshaft balancer aligns with the mark (1) on the engine front cover.
6. Install EN-49979 crankshaft shock mount retainer (1) to suitable tool (2).
7. Loosen the crankshaft balancer bolt (4) while holding the crankshaft balancer (3).
8. Remove and DISCARD the crankshaft balancer bolt (2).
9. Remove the crankshaft balancer (1).

1. Install the crankshaft balancer carefully by pressing into position.
2. Measure the distance (a) between the crankshaft balancer (2) and the mark on the engine front cover (1). The distance (a) should be 5.5 mm (0.21654 in).
3. Install a NEW crankshaft balancer bolt.
4. Tighten the crankshaft balancer bolt (4) to 150 N•m (111 lb ft) while holding the crankshaft balancer (3) with EN-49979 crankshaft shock mount retainer (1) and suitable tool (2). Use EN-470-B wrench .
5. Tighten the crankshaft balancer bolt to an additional 60°.
6. Install the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
7. Install the front wheelhouse liner extension right side. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
8. Lower the vehicle.
9. Check and correct engine oil level.

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-542544-S19425945882013041600000) .
2. Place a drain pan underneath the front crankshaft seal area.
3. Remove crankshaft front oil seal (2) from engine front cover. Use EN-45000 remover (1).

1. Install NEW crankshaft front oil seal (1) to EN-960 installer (2).
2. Install crankshaft front oil seal by means of EN-960 installer (1) to engine front cover (2).
3. Ensure that crankshaft front oil seal (2) is flush with engine front cover (1).
4. Install crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-542544-S19425945882013041600000) .
5. Remove the drain pan.
6. Check and correct engine oil level.

1. If equipped with automatic transmission remove the flex plate. Refer to «Automatic Transmission Flex Plate Replacement»(ref-542544-S26362154732013041600000) .
2. If equipped with manual transmission remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-542544-S26702791402013041600000)
3. Using a flat-bladed tool, remove the rear crankshaft oil seal (1).

1. Install the crankshaft rear oil seal (1) with EN-658 installer (2).
2. Using the EN-658 installer (2) , install a NEW crankshaft real oil seal (1).
3. If equipped with automatic transmission install the flex plate. Refer to «Automatic Transmission Flex Plate Replacement»(ref-542544-S26362154732013041600000) .
4. If equipped with manual transmission install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-542544-S26702791402013041600000)

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
2. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
3. Remove the positive crankcase ventilation pipe from the intake manifold.
4. Loosen the charger air bypass valve pipe clamp (3).
5. Remove the charger air bypass valve pipe from turbocharger.
6. Remove the charger air bypass valve pipe (2) from turbo charger wastegate regulator solenoid valve.
7. Disconnect the positive crankcase ventilation pipe from turbocharger.
8. Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer clips.

1. Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
2. Connect the positive crankcase ventilation pipe to turbocharger.
3. Install the charger air bypass valve pipe (2) to turbo charger wastegate regulator solenoid valve.
4. Install the charger air bypass valve pipe to turbocharger.
5. Fasten the charger air bypass valve pipe clamp (3).
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .

Scheme 59

Engine Oil Heater Replacement

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
2. Set the engine to TDC. Refer to «Camshaft Timing Chain Inspection»(ref-542544-S34513644892013041600000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
4. Remove the front wheelhouse liner extension, right side. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
5. Remove the air conditioning compressor. Refer to «Air Conditioning Compressor Replacement (LUV)»(ref-542551-S00682742682013041600000) .
6. Remove the air conditioning compressor bracket. Refer to «Air Conditioning Compressor Bracket Removal»(ref-542544-S02420596732013041600000) .
7. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-542544-S19425945882013041600000) .
8. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-542544-S14919510592013041600000) .
9. Lower vehicle.
10. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-542544-S20978662672013041600000) .
11. Remove the generator from above. Refer to «Generator Replacement (LUV)»(ref-542503-S28913242842013041600000) .
12. Remove the water pump pulley and the water pump. Refer to «Water Pump Replacement (LUV)»(ref-542500-S15179259792013041600000) .
13. Remove the camshaft position actuator solenoid valves. Refer to «Camshaft Position Actuator Solenoid Valve Removal»(ref-542544-S40055718092013041600000) .
14. Loosen the camshaft sprocket bolts until the camshaft position exciter wheels are free to rotate. Refer to «Camshaft Timing Chain Adjustment»(ref-542544-S21827986062013041600000) .
15. Remove the 13 engine front cover bolts M6 (1).
16. Remove the 2 engine front cover bolts M10 (2).
17. Remove the engine front cover (3).
18. Remove the camshaft timing chain. Refer to «Camshaft Timing Chain Replacement»(ref-542544-S11578940052013041600000) .
19. Remove the engine front cover gasket (1).
20. Remove the intake and exhaust camshaft position sensors from the engine front cover. Refer to «Camshaft Position Sensor Replacement»(ref-542528-S39614631702013041600000) .

1. Install the intake and exhaust camshaft position sensors to the engine front cover. Refer to «Camshaft Position Sensor Replacement»(ref-542528-S39614631702013041600000) .
2. Clean the engine front cover sealing surfaces on engine block and cylinder head.
3. Apply sealing compound to the shown areas (1) and (2). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
4. Install a NEW engine front cover gasket (1).
5. Install the timing chain. Refer to «Camshaft Timing Chain Replacement»(ref-542544-S11578940052013041600000) .
6. Install the engine front cover (3).
7. Install the 13 engine front cover bolts M6 (1).
8. Install the 2 engine front cover bolts M10 (2).
9. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).
10. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).
11. Tighten the camshaft sprockets, install the upper timing chain guide and remove all special tools. Refer to «Camshaft Timing Chain Adjustment»(ref-542544-S21827986062013041600000) .
12. Install the 2 camshaft position actuator solenoid valves. Refer to «Camshaft Position Actuator Solenoid Valve Replacement»(ref-542528-S02046342552013041600000) .
13. Install the water pump and the water pump pulley. Refer to «Water Pump Replacement (LUV)»(ref-542500-S15179259792013041600000) .
14. Install the generator from above. Refer to «Generator Replacement (LUV)»(ref-542503-S28913242842013041600000) .
15. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-542544-S20978662672013041600000) .
16. Install the air conditioning compressor bracket. Refer to «Air Conditioning Compressor Bracket Installation»(ref-542544-S29167577412013041600000) .
17. Install the air conditioning compressor. Refer to «Air Conditioning Compressor Replacement (LUV)»(ref-542551-S00682742682013041600000) .
18. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-542544-S19425945882013041600000) .
19. Install the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
20. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
21. Install the engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-542544-S41377953382013041600000) .
22. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-542544-S24703244862013041600000) .
23. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-542528-S25099370852013041600000) .
24. Raise the vehicle.
25. Install the oil pan. Refer to «Oil Pan Replacement»(ref-542544-S14919510592013041600000) .
26. Install the front wheelhouse liner extension, right side. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) .
27. Lower the vehicle.
28. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
29. Fill up engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-542544-S16162666712013041600000) .

1. Remove the engine front cover. Refer to «Engine Front Cover with Oil Pump Replacement»(ref-542544-S15979241822013041600000) .
2. Remove the 8 oil pump cover bolts (1).
3. Remove the oil pump cover (2).
4. Protect the engine front cover edge (1) with a suitable piece of plastic.
5. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring in conjunction with the oil pump slide spring pin.
6. Remove the oil pump components in the following order: Outer oil pump vane ring (1). Oil pump vane rotor (3) and the 7 oil pump vanes (2). Inner oil pump vane ring (6). Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).

1. Install the oil pump components in the following order: NOTE: The bore (8) in the oil pump slide must fit smooth-running and without clearance to the oil pump slide pivot pin (7). Install the oil pump slide (6). Install the inner oil pump vane ring (5). NOTE: Ensure the mark (9) of the oil pump vane rotor (4) points to the oil pump cover. Install the oil pump vane rotor (4). NOTE: Ensure the flats (3) on the oil pump vanes (2) point to the oil pump vane rotor. Install the 7 oil pump vanes (2). Install the outer oil pump vane ring (1).
2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2 grooves (1) of the oil pump slide.
3. Protect the engine front cover edge (5) with a suitable piece of plastic.
4. Install the oil pump slide spring pin (1) in conjunction with the oil pump slide spring (4). Use a screwdriver to compress the oil pump slide spring. The flat side of oil pump slide spring pin must face upwards.
5. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the chambers (3) with engine oil.
6. Inspect the oil pump slide spring mechanism for proper function.
7. Measure the oil pump axial and radial clearances and compare with the specified values. Refer to «Engine Front Cover and Oil Pump Cleaning and Inspection»(ref-542544-S00028493962013041600000) .
8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).
9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).
10. Install the crankshaft balancer (1) and rotate in shown direction (2) in order to inspect the function of the oil pump mechanism. Crankshaft balancer should rotate easily.
11. Remove the timing chain and replace the engine front cover gasket. Refer to «Camshaft Timing Chain Replacement»(ref-542544-S11578940052013041600000) .
12. Install the timing chain. Refer to «Camshaft Timing Chain Replacement»(ref-542544-S11578940052013041600000) .
13. Install the engine front cover. Refer to «Engine Front Cover with Oil Pump Replacement»(ref-542544-S15979241822013041600000) .
14. Measure the oil pressure and compare with the specified values. Refer to «Oil Pressure Diagnosis and Testing»(ref-542544-S38691713142013041600000) .

1. Remove the battery and battery tray. Refer to «Battery Tray Replacement»(ref-542503-S09850153572013041600000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-542510-S32278463372013041600000) .
3. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-542551-S18518122652013041600000) .
4. Remove the front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
5. Remove the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-542484-S28756343532013041600000) .
6. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
7. Remove the lower intermediate steering shaft bolt (1) and slide the shaft away from steering column. Refer to «Intermediate Steering Shaft Replacement»(ref-542491-S38156966972013041600000) .
8. Remove the air cleaner assembly (1). Refer to «Air Cleaner Assembly Replacement»(ref-542510-S25363651482013041600000) .
9. Remove the junction block cover (1).
10. Remove the positive battery cable nut (1) from the junction block.
11. Remove the positive battery cable (2) from the junction block.
12. Remove the positive cable nut (1) and battery positive cable, from the battery positive cable junction block.
13. Disconnect the body wiring master harness connector (2), from the battery positive cable junction block.
14. Remove the junction block nut (1).
15. Remove the junction block bolts (2).
16. Disconnect the wiring harness from the junction block base.
17. Remove the junction block (3) from the base.
18. Disconnect the wiring harness plug from the front compartment fuse block.
19. Reposition the wiring harness (1) on top of the engine.
20. Remove the ground nuts (1) and reposition the wiring harness (2) aside.
21. Disconnect the electrical connector and remove the brake booster hose (1) .
22. Disconnect the heater inlet hose (1) from the heater core. Refer to «Heater Inlet Hose Replacement (LUV)»(ref-542551-S14895214842013041600000) .
23. Disconnect the heater outlet hose (1) from the heater core. Refer to «Heater Outlet Hose Replacement (LUV)»(ref-542551-S12091355482013041600000) .
24. If equipped with an automatic transmission, disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
25. Remove the transmission range selector lever cable (2) from the cable bracket.
26. If equipped with manual transmission, disconnect the shift lever and selector lever cable end (1) from the transmission shift lever and selector lever.
27. Pull the cable retainers (2) to release the shift lever and selector lever cable from the shift lever and selector lever cable bracket.
28. Disconnect the shift lever and selector lever cable from the shift lever and selector lever cable bracket.
29. Remove the radiator surge tank (2) and position aside. Refer to «Radiator Surge Tank Replacement»(ref-542500-S06056294982013041600000) .
30. Disconnect the fan connector.
31. Remove air conditioning compressor and condenser hose nut (1).
32. Remove air conditioning compressor and condenser hose (2) from refrigerant hose.
33. Disconnect the fuel feed pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-542528-S35469047292013041600000) .
34. Disconnect the evaporative emission pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-542528-S35469047292013041600000) .
35. Remove the wheel drive shafts. Refer to «Front Wheel Drive Shaft Replacement»(ref-542524-S06936399752013041600000) .
36. Remove the front exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV,LUW)»(ref-542543-S08102879492013041600000) .
37. If equipped with an automatic transmission, remove the lower transmission nut (1) and the lower transmission bolts (2, 3, 4).
38. If equipped with manual transmission, remove the lower transmission bolt (3) and nut (4).
39. Remove the lower transmission bolts (1, 2).
40. Remove the frame front bolts (1).
41. Position the EN-48244 engine assembly remove/install pallet supporter under the powertrain and support with blocks of wood.
42. Remove the upper frame suspension retaining bolts (1) on both sides.
43. Remove the right side engine mount (4). Refer to «Engine Mount Replacement - Right Side»(ref-542544-S41377953382013041600000) .
44. Remove and DISCARD the transmission mount bolts (1) - left side. Refer to «Transmission Mount Replacement - Left Side»(ref-542509-S25291260542013041600000) .
45. Disconnect any additional electrical connections as necessary.
46. Raise the vehicle until the powertrain is clear for removal.
47. If equipped with an automatic transmission, remove the starter. Refer to «Starter Replacement (LUV)»(ref-542503-S32233069872013041600000) .
48. Mark the relationship of the flex plate to the torque converter for reassembly.
49. Remove and DISCARD the flex plate to torque converter bolts (1).
50. If equipped with an automatic transmission, remove the upper transmission to engine bolts (1) and separate the engine and transmission.
51. If equipped with manual transmission, remove the upper transmission to engine bolts (1). And separate the engine and transmission.
52. Disconnect any electrical connectors as needed.
53. Transfer parts as necessary.

1. Install the transmission to the engine.
2. If equipped with a manual transmission, install the upper transmission to engine bolts (1) to 60 (44 lb ft).
3. If equipped with automatic transmission, install the upper transmission to engine bolts (1) and tighten to 60 (44 lb ft).
4. If equipped with an automatic transmission, install the torque converter to flex plate bolts (1) and tighten to 60 (44 lb ft).
5. Install the starter. Refer to «Starter Replacement (LUV)»(ref-542503-S32233069872013041600000) .
6. Position the powertrain under the vehicle and slowly lower the body onto the powertrain.
7. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 (37 lb ft) plus 70 degrees.
8. Install the right side engine mount (4). Refer to «Engine Mount Replacement - Right Side»(ref-542544-S41377953382013041600000) .
9. Connect all previously disconnected electrical connections.
10. Install the frame (3) rear bolts (2) and front bolts (1), tighten a little bit.
11. Install the frame (3) rear bolts (2) and tighten to 135 (100 lb ft).
12. Install the frame (3) front bolts (1) and tighten to 58 (43 lb ft).
13. Install the upper frame suspension retaining bolts (1) on both sides and tighten to 135 (100 lb ft).
14. Remove the lift table.
15. If equipped with manual transmission, install the lower transmission bolts (1) and tighten to 60 (44 lb ft).
16. Install the lower transmission bolts (2) and tighten 40 (30 lb ft).
17. Install the lower transmission bolt (3) and nut (4) and tighten to 40 (30 lb ft).
18. If equipped with an automatic transmission, install the lower transmission bolts (2, 4) and tighten to 60 (44 lb ft).
19. Install the lower transmission bolts (3) and the lower transmission nut (1) and tighten to 40 (30 lb ft).
20. Install the front exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV,LUW)»(ref-542543-S08102879492013041600000) .
21. Install the wheel drive shafts. Refer to «Front Wheel Drive Shaft Replacement»(ref-542524-S06936399752013041600000) .
22. Connect the evaporative emission pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-542528-S35469047292013041600000) .
23. Connect the fuel feed pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-542528-S35469047292013041600000) .
24. Install air conditioning compressor and condenser hose to the refrigerant hose.
25. Install air conditioning compressor and condenser hose nut (1) tighten nut to 22 (16 lb ft).
26. Install the radiator surge tank (2). Refer to «Radiator Surge Tank Replacement»(ref-542500-S06056294982013041600000) .
27. Connect the fan connector.
28. If equipped with manual transmission, Connect the shift lever and selector lever cable end (1) to the transmission shift lever and selector lever.
29. Connect the shift lever and selector lever cable to the shift lever and selector lever cable bracket.
30. Install the cable retainers (2) to the shift lever and selector lever cable bracket.
31. If equipped with automatic transmission, install the transmission range selector lever cable (2) to the cable bracket.
32. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
33. Adjust the automatic transmission range selector lever cable. Refer to «Range Selector Lever Cable Adjustment»(ref-542509-S39524719042013041600000) .
34. Connect the heater inlet hose (2) from the heater core. Refer to «Heater Inlet Hose Replacement (LUV)»(ref-542551-S14895214842013041600000) .
35. Connect the heater outlet hose (2) from the heater core. Refer to «Heater Outlet Hose Replacement (LUV)»(ref-542551-S12091355482013041600000) .
36. Connect the electrical connector and install the brake booster hose (1).
37. Install the ground nuts (1) and wiring harness (2).
38. Clip in the wiring harness plugs (1).
39. Install the junction block to the base (3).
40. Install the junction block bolts (2) and tighten to 5 (44 lb in).
41. Install the junction block nut (1) and tighten to 5 (44 lb in).
42. Install the battery positive cable to the battery positive cable junction block and tighten nut (1) to 5 (44 lb in).
43. Connect the body wiring master harness connector (2), to the battery positive cable junction block.
44. Position the positive battery cable (2) to the junction block.
45. Install the positive battery cable nut (1) and tighten to 7 (62 lb in).
46. Install the junction block cover (1).
47. Install the air cleaner assembly (1). Refer to «Air Cleaner Assembly Replacement»(ref-542510-S25363651482013041600000) .
48. Install the lower intermediate steering shaft bolt (1). Refer to «Intermediate Steering Shaft Replacement»(ref-542491-S38156966972013041600000) .
49. Install the battery and battery tray. Refer «Battery Tray Replacement»(ref-542503-S09850153572013041600000) .
50. Install the front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
51. Install the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-542484-S28756343532013041600000) .
52. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-542551-S18518122652013041600000) .
53. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .

1. Open hood.
2. Place a drain pan below the vehicle.
3. Using a 24mm socket or closed end wrench loosen oil filter cap. Unscrew filter cap 3 turns and let oil filter and cap assembly drain in housing for 30 seconds.
4. Remove the engine oil filter cap (2) with the engine oil filter cap seal ring (3) and the oil filter element (1).
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
6. Remove the oil pan drain plug and allow the oil to drain into the drain pan.

1. Clean the oil pan drain plug thread in the oil pan.
2. Install a NEW seal ring to the oil pan drain plug.
3. Install the oil pan drain plug and tighten to 14 N.m (10 lb ft).
4. Lower the vehicle.
5. Install a NEW oil filter cap seal ring (1).
6. Install the engine oil filter cap (2) with NEW engine oil filter cap seal ring (3) and NEW oil filter element (1) hand tight.
7. Using a 24mm socket or closed end wrench tighten the engine oil filter cap to 25 N.m (18 lb ft).
8. Fill engine with NEW oil using Dexos™1 5W-30 specification.
9. Install oil fill cap.
10. Start the engine and allow it to run until the oil pressure control indicator goes off. Inspect for any oil leaks around the drain plug, oil filter and oil fill cap.
11. Inspect the engine oil level. The oil level should be in the cross-hatched section of the oil level indicator as shown.
12. Close hood.
13. Reset the engine oil life system monitor.

1. Disconnect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
4. Disconnect the positive crankcase ventilation pipe from turbocharger. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(ref-542544-S18562001742013041600000) .
5. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) .
6. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and unclip wiring harness from retainer clip (2).
7. Remove the turbocharger oil feed pipe hollow screw (4).
8. Remove and DISCARD the 2 seal rings (1) and (3).
9. Remove the turbocharger oil feed pipe bolt (5).
10. Remove the turbocharger oil feed pipe (2).
11. Loosen the turbocharger coolant return hose clamp and remove the turbocharger coolant return hose (6) from the oil cooler inlet pipe.
12. Remove the turbocharger coolant return pipe bolt (7).
13. Remove the charge air cooler inlet air hose from the turbocharger. Refer to «Charge Air Cooler Inlet Air Hose Replacement»(ref-542528-S21801924182013041600000) .
14. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
15. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).
16. Remove the turbocharger coolant feed pipe hollow screw.
17. Remove and DISCARD the 2 seal rings.
18. Remove the three way warm catalytic converter. Refer to «Catalytic Converter Replacement (LUV)»(ref-542543-S28635637502013041600000) .
19. Remove the 2 turbocharger oil return pipe bolts (1) from turbocharger.
20. Remove the turbocharger oil return pipe from the turbocharger.
21. Remove and DISCARD the gasket.
22. Remove and DISCARD the 8 turbocharger nuts (1).
23. Remove the turbocharger assembly (1).
24. Remove and DISCARD the turbocharger gasket (2).
25. Remove the assembly parts from the turbocharger as necessary. Refer to «Turbocharger Disassemble»(ref-542544-S17114921312013041600000) .
26. If the turbocharger is being reused, refer to «Turbocharger Cleaning and Inspection»(ref-542544-S40409406382013041600000) .

1. Install the assembly parts to the turbocharger as necessary. Refer to «Turbocharger Assemble»(ref-542544-S02108635212013041600000) .
2. Clean the sealing surfaces.
3. Install a NEW turbocharger gasket.
4. Install the turbocharger assembly (1).
5. Install the 8 NEW turbocharger nuts (1).
6. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).
7. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.
8. Install a NEW gasket and the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).
9. Install the three way warm up catalytic converter. Refer to «Catalytic Converter Replacement (LUV)»(ref-542543-S28635637502013041600000) .
10. Install the turbocharger coolant feed pipe to the engine block. Use the following procedure: Install a NEW seal ring (3) to the turbocharger coolant feed pipe hollow screw (4). Install the turbocharger coolant feed pipe hollow screw along with the seal ring to the turbocharger coolant feed pipe (2). Install a NEW seal ring (1) to the turbocharger coolant feed pipe hollow screw. Install the turbocharger coolant feed pipe hollow screw along with the turbocharger coolant feed pipe and the 2 seal rings to the engine.
11. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
12. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m (22 lb ft).
13. Install the charge air cooler inlet air hose to the turbocharger. Refer to «Charge Air Cooler Inlet Air Hose Replacement»(ref-542528-S21801924182013041600000) .
14. Install the turbocharger coolant return pipe bolt (7) and tighten to 8 N.m (71 lb in).
15. Install the turbocharger coolant return hose (6) to the oil cooler inlet pipe.
16. Install the turbocharger coolant return hose clamp.
17. Install the turbocharger oil feed pipe (2) to the oil cooler and the turbocharger.
18. Install the turbocharger oil feed pipe bolt (5).
19. Install the turbocharger oil feed pipe hollow screw (4) along with the 2 NEW seal rings (1) and (3) and tighten to 30 N.m (22 lb ft).
20. Tighten the turbocharger oil feed pipe bolt to 10 N.m (89 lb in).
21. Connect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and clip in wiring harness to retainer clip (2).
22. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) .
23. Connect the positive crankcase ventilation pipe to the turbocharger. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(ref-542544-S18562001742013041600000) .
24. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
25. Connect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
26. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
27. Use a scan tool to perform the Engine Control Module Setup for Component Replacement. Refer to «Control Module References»(ref-542499-S01936129122013041600000) .

1. Open the hood.
2. Disconnect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
3. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) .
4. Remove the turbocharger oil feed pipe bolt (5).
5. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3).
6. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.

1. Clean the sealing surfaces.
2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1) and (3).
4. Install the turbocharger oil feed pipe bolt (5) and tighten to 10 N.m (89 lb in).
5. Tighten the turbocharger oil feed pipe hollow screw to 30 N.m (22 lb ft).
6. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) .
7. Connect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
8. Close the hood.

1. Remove the drivetrain and front suspension frame skid plate, if equipped. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .
2. Remove the 2 turbocharger oil return pipe bolts (1).
3. Place a drain pan below the vehicle.
4. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe from the engine block.
5. Remove the turbocharger oil return pipe (2) and the gasket (3).

1. Clean the sealing surfaces.
2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine block.
3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).
4. Lower the vehicle.
5. Check engine oil level.
6. Install the drivetrain and front suspension frame skid plate, if equipped. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .

Scheme 60

Camshaft Cover Replacement

1. Remove the camshaft intake and exhaust sprocket. Refer to «Camshaft Intake and Exhaust Sprocket Replacement»(ref-542544-S24276862332013041600000) .
2. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time until there is no spring tension pushing on the camshaft.
3. Remove the camshaft bearing cap bolts (1).
4. Remove the camshaft bearing caps (2).
5. Remove the intake camshaft (3).

1. Lubricate the camshaft and camshaft bearing caps with engine oil.
2. Install the intake camshaft (3).
3. Install the camshaft bearing caps (2).
4. Install the camshaft bearing cap bolts and tighten the bolts hand tight (1).
5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown to 8 N.m (71 lb in).
6. Install the camshaft intake and exhaust sprocket. Refer to «Camshaft Intake and Exhaust Sprocket Replacement»(ref-542544-S24276862332013041600000) .

1. Remove the camshaft intake and exhaust sprocket. Refer to «Camshaft Intake and Exhaust Sprocket Replacement»(ref-542544-S24276862332013041600000) .
2. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).
3. Allow the both camshaft sprockets with the timing chain to rest on the engine front cover.
4. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time until there is no spring tension pushing on the camshaft.
5. Remove the camshaft bearing cap bolts (1).
6. Remove the camshaft bearing caps (2).
7. Remove the exhaust camshaft (3).

1. Lubricate camshaft and camshaft bearing caps with engine oil.
2. Install the exhaust camshaft (3).
3. Install the camshaft bearing caps (2).
4. Install the camshaft bearing cap and hand tighten the bolts (1).
5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown 8 N.m (71 lb in).
6. Install the camshaft intake and exhaust sprocket. Refer to «Camshaft Intake and Exhaust Sprocket Replacement»(ref-542544-S24276862332013041600000) .

Scheme 61

Engine Support Fixture

Engine Mount Bracket Removal

1. Remove the 3 engine mount bracket bolts (1).
2. Remove the engine mount bracket (2).

Draining Fluids and Oil Filter Removal

1. Remove the engine oil filter cap (2) along with the engine oil filter cap seal ring (3) and the oil filter element (1).
2. Remove the oil pan drain plug and allow the oil to drain out.
3. Install the oil pan drain plug and a NEW seal ring and tighten to 14 N.m (124 lb in).
4. Install the engine oil filter cap along with a NEW engine oil filter cap seal ring and a NEW oil filter element.
5. Tighten the engine oil filter cap to 25 N.m (18 lb ft).
6. Remove the water pump drain plug (1) and the water pump drain plug seal ring (2) and allow the remaining coolant to drain out.
7. Install the water pump drain plug and a NEW seal ring and tighten to 15 N.m (11 lb ft).

Positive Crankcase Ventilation Pipe Removal

1. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
2. Remove the positive crankcase ventilation pipe from the intake manifold.
3. Loosen the charger air bypass valve pipe clamp (4).
4. Remove the charger air bypass valve pipe from turbocharger.
5. Remove the charger air bypass valve pipe (2) from turbo charger waste regulator solenoid valve.
6. Disconnect the positive crankcase ventilation pipe from turbocharger (3).
7. Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer clips.

Exhaust Manifold Heat Shield Removal

1. Remove the 3 exhaust manifold heat shield bolts (1) and the washers.
2. Remove the exhaust manifold heat shield (2).

Warm Up Three-Way Catalytic Converter Removal

1. Disconnect the heated oxygen sensor wiring harness (3) from retainer clip.
2. Remove the 2 catalytic converter to catalytic converter bracket nuts (4) and (6).
3. Loosen the three way warm up catalytic converter V-clamp (1).
4. Remove the three way warm up catalytic converter (5) and the catalytic converter seal (2).

Turbocharger Removal

Special Tool

EN-49942 Holding Wrench

For equivalent regional tools, refer to Special Tools .

1. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
2. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).
3. Remove the turbocharger coolant feed pipe hollow screw (3) and the 2 seal rings (1) and (2).
4. Disconnect the turbocharger oil return pipe (4) from the engine block.
5. Remove the turbocharger oil feed pipe bolt (5) from the oil cooler.
6. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3) and close the screw bore in the turbocharger.
7. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.
8. Disconnect the turbocharger coolant return hose (6) from the oil cooler coolant inlet pipe and remove the turbocharger coolant return pipe bolt (7) from the oil cooler.
9. Remove the 8 turbocharger nuts (1).
10. Remove the turbocharger assembly (1) and the turbocharger gasket (2).

Engine Oil Cooler Removal

1. Remove the oil cooler coolant outlet hose clamp (1).
2. Remove the oil cooler coolant outlet hose (2) from engine coolant thermostat housing.
3. Remove the oil cooler coolant inlet hose clamp (3).
4. Remove the oil cooler coolant inlet hose (4) from water outlet.
5. Remove the oil cooler coolant outlet pipe bolt (7).
6. Remove the 3 oil cooler bolts (5).
7. Remove the engine oil cooler assembly (6) and the 2 oil cooler sealings (8) and (9).

Engine Coolant Thermostat Housing Removal

1. Remove the 3 engine coolant thermostat housing bolts (1).
2. Remove the engine coolant thermostat housing (2) and the engine coolant thermostat housing seal ring (3).

Water Outlet Removal

1. Remove the 3 water outlet bolts (3).
2. Remove the water outlet (2) and the water outlet seal ring (1).

Drive Belt Tensioner Removal

1. Remove the upper drive belt tensioner bolt (2).
2. Remove the lower drive belt tensioner bolt (3).
3. Remove the drive belt tensioner (1).

Air Conditioning Compressor Bracket Removal

1. Remove the 3 air conditioning compressor bracket bolts (1).
2. Remove the air conditioning compressor bracket (2).

Water Pump Pulley Removal

1. Loosen the 3 water pump pulley bolts (2) while holding up the water pump pulley hub with a wrench.
2. Remove the 3 water pump pulley bolts (2).
3. Remove the water pump pulley (1).

Crankshaft Balancer Removal

Special Tools

1. EN-956-1 Extension
2. EN-49979 Crankshaft Shock Mount Retainer

For equivalent regional tools, refer to Special Tools .

1. Install EN-49979 retainer to EN-956-1 extension.
2. Loosen the crankshaft balancer bolt (4) while fixing the crankshaft balancer (3) with EN-49979 retainer (1) and EN-956-1 extension (2).
3. Remove and DISCARD the crankshaft balancer bolt (2).
4. Remove the crankshaft balancer (1).

Water Pump Removal

1. Remove the 5 short water pump bolts (4) and the 5 long water pump bolts (3).
2. Remove the water pump (2).
3. Remove the water pump gasket (1).

Throttle Body Removal

1. Remove the 4 throttle body bolts (3).
2. Remove the throttle body (2) and the throttle body seal ring (1).

Intake Manifold Removal

1. Remove the 6 intake manifold bolts (1).
2. Remove the intake manifold (1) along with the intake manifold gasket.

Generator Removal

1. Remove the 2 generator bolts (2).
2. Remove the generator (1).

Starter Removal

1. Remove the upper starter bolt (2) and if equipped the washer (1).
2. Remove the lower starter bolt stud (3) and if equipped the washer.
3. Remove the starter (4).

Engine Flywheel Removal

Special Tools

EN-652 Flywheel Holder

For equivalent regional tools, refer to Special Tools .

1. Install EN-652 holder (1) to hold the engine flywheel (2).
2. Remove and DISCARD the 6 engine flywheel bolts (2).
3. Remove the engine flywheel (1).

Ignition Coil Removal

Special Tools

EN-6009 Remover and Installer Ignition Module

For equivalent regional tools, refer to Special Tools .

1. Remove the 2 ignition coil bolts (1).
2. Install EN-6009 remover and installer (2) and remove the ignition coil (1).

Camshaft Cover Removal

1. Remove the oil level indicator (1).
2. Remove the 15 camshaft cover bolts (1).
3. Remove the camshaft cover (2) and the camshaft cover gasket (3).

Camshaft Position Actuator Solenoid Valve Removal

1. Remove the 4 camshaft position actuator solenoid valve bolts (1).
2. Move the intake camshaft position actuator solenoid valve (1) carefully counter clockwise in the position shown.
3. Move the exhaust camshaft position actuator solenoid valve (2) carefully clockwise in the position shown.
4. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1).

Oil Pan Removal

1. Remove the 16 oil pan bolts (1).
2. Place a suitable prying tool to the area shown (1) and carefully pry the oil pan loose.
3. Remove the oil pan (1).

Engine Front Cover and Oil Pump Removal

1. Set engine to TDC. Refer to «Camshaft Timing Chain Inspection»(ref-542544-S34513644892013041600000) .
2. Remove the 13 engine front cover bolts M6 (1).
3. Remove the 2 engine front cover bolts M10 (2).
4. Remove the engine front cover.

Camshaft Timing Chain Removal

Special Tools

1. EN-952 Fixing Pin
2. EN-953-A Fixing Tool
3. EN-955-10 Fixing Pin from EN-955 Kit

For equivalent regional tools, refer to Special Tools .

1. The engine should be adjusted to TDC.
2. The crankshaft should be fixed with EN-952 fixing pin.
3. The camshaft should be fixed with EN-953-A fixing tool.
4. Push the timing chain (2) in direction to the timing chain tensioner (1) and fix the tensioner with EN-955-10 fixing pin (3).
5. Remove the 2 upper timing chain guide bolts (1).
6. Remove the upper timing chain guide (2).
7. Remove the 2 timing chain guide right side bolts (2).
8. Remove the timing chain guide right side (1).
9. Remove the timing chain tensioner shoe bolt (2).
10. Remove the timing chain tensioner shoe (1).
11. Remove the timing chain (1) in compound with the crankshaft sprocket (2).

Timing Chain Tensioner Removal

1. Remove the 2 timing chain tensioner bolts (1).
2. Remove the timing chain tensioner (2).

Scheme 62

Remove and DISCARD the engine front cover gasket (1).

Camshaft Sprocket Removal

1. Loosen the intake camshaft sprocket bolt (1) while holding the hexagon of intake camshaft (2) with a wrench.
2. Remove the intake camshaft sprocket bolt (1) and the intake camshaft position exciter wheel (2).
3. Remove the intake camshaft sprocket (3).
4. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of exhaust camshaft with a wrench.
5. Remove the exhaust camshaft sprocket bolt and the exhaust camshaft position exciter wheel.
6. Remove the exhaust camshaft sprocket.

Intake Camshaft Removal

1. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no spring tension pushing on the camshaft.
2. Remove the 10 camshaft bearing cap bolts (1).
3. Remove the 5 camshaft bearing caps (2).
4. Remove the intake camshaft (3).

Exhaust Camshaft Removal

1. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no spring tension pushing on the camshaft.
2. Remove the 10 camshaft bearing cap bolts (1).
3. Remove the 5 camshaft bearing caps (2).
4. Remove the exhaust camshaft (3).

Scheme 63

Note. Mind the installation position of the hydraulic valve lash adjuster arms.

Remove the 16 hydraulic valve lash adjuster arms (1).

Scheme 64

Note. Mind the installation position of the hydraulic valve lash adjusters.

Remove the 16 hydraulic valve lash adjusters (1).

Cylinder Head Removal

1. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure: Loosen the cylinder head bolts 90 degrees. Loosen the cylinder head bolts 180 degrees.
2. Remove the 12 cylinder head bolts (1).
3. Remove the cylinder head (2).
4. Remove the cylinder head gasket (3).

Piston, Connecting Rod, and Bearing Removal

1. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3.
2. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3.
3. Rotate the crankshaft 180 degrees.
4. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4.
5. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4.
6. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the cylinder block.

Crankshaft and Bearing Removal

1. Remove the crankshaft position sensor bolt (3).
2. Remove the crankshaft position sensor (1) and the crankshaft position sensor seal ring (2).
3. Remove the 12 outer crankshaft bearing cap tie plate bolts (1).
4. Loosen the 10 inner crankshaft bearing cap tie plate bolts in a sequence as shown.
5. Remove and DISCARD the 10 crankshaft bearing cap tie plate bolts (1) Remove the crankshaft bearing cap tie plate (2).
6. Remove the 4 lower crankshaft bearings (3) an the lower crankshaft thrust bearing (4).
7. Remove the crankshaft rear oil seal (5).
8. Remove the crankshaft (1), the 4 upper crankshaft bearings (2) and the upper crankshaft thrust bearing (3).

Oil Pump Removal

1. Remove the 8 oil pump cover bolts (1).
2. Remove the oil pump cover (2).
3. Protect the engine front cover edge (1) with a suitable piece of plastic.
4. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring along with the oil pump slide spring pin.
5. Remove the oil pump components in the following order: Outer oil pump vane ring (1). Oil pump vane rotor (3) and the 7 oil pump vanes (2). Inner oil pump vane ring (6). Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).

Crankshaft and Bearing Installation

Special Tools

1. EN-235-6 Installer from EN-235-D Kit.
2. EN-470-B Angular Torque Wrench
3. EN-658-1 Installer from EN-658 Kit.

For equivalent regional tools, refer to Special Tools .

1. Lubricate crankshaft, crankshaft bearings and crankshaft bearing cap tie plate with engine oil.
2. Install the 4 upper crankshaft bearings (2) and the crankshaft thrust bearing (3).
3. Install the crankshaft (1).
4. Apply sealing compound (1) to the outer rim of the groove on the crankshaft bearing cap tie plate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
5. Install the 4 lower crankshaft bearings (3) and the lower crankshaft thrust bearing (4).
6. Install the crankshaft bearing cap tie plate (2).
7. Install the 10 NEW inner crankshaft bearing cap tie plate bolts (1).
8. Tighten the 10 inner crankshaft bearing cap tie plate bolts in the sequence shown and to the following specifications: Tighten the inner crankshaft bearing cap tie plate bolts to 25 N.m (18 lb ft). Tighten the inner crankshaft bearing cap tie plate bolts an additional 60 degrees. Use EN-470-B wrench. Tighten the inner crankshaft bearing cap tie plate bolts an additional 15 degrees. Use EN-470-B wrench.
9. Install the 12 NEW outer crankshaft bearing cap tie plate bolts (1) and tighten to the following specification: Tighten the outer crankshaft bearing cap tie plate bolts to 10 N.m (89 lb in). Tighten the outer crankshaft bearing cap tie plate bolts an additional 60 degrees. Use EN-470-B wrench. Tighten the outer crankshaft bearing cap tie plate bolts an additional 15 degrees. Use EN-470-B wrench.
10. Install the crankshaft position sensor (1) and a NEW crankshaft position sensor seal ring (2).
11. Install the crankshaft position sensor bolt (3) and tighten to 8 N.m (71 lb in).
12. Slide the crankshaft rear oil seal (2) across the EN-235-6 installer (1) contained in EN-235-D kit.
13. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2) to the crankshaft.
14. Use EN-658-1 installer (2) to strike the crankshaft rear oil seal (1)

Piston, Connecting Rod, and Bearing Installation

Special Tools

EN-470-B Angular Torque Wrench

For equivalent regional tools, refer to Special Tools .

1. Adjust the piston ring joints as follows: Upper compression ring (1). Lower compression ring (4). Oil rings (2) or (3). Oil ring spacer (5).
2. The arrow (1) on the piston head must point to the timing side.
3. The markings on the connecting rods (2) must point to the transmission side.
4. Install a piston ring compressor to compress the piston rings.
5. Install the pistons (1) in along with connecting rods (2) and upper connecting rod bearings (3) to the engine block and to the crankshaft.
6. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4.
7. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470 B wrench.
8. Rotate the crankshaft 180 degrees.
9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2.
10. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470-B wrench.

Cylinder Head Installation

Special Tools

EN-470-B Angular Torque Wrench.

For equivalent regional tools, refer to Special Tools .

1. Clean the sealing surfaces and remove dirt and old gasket material from thread bores, water galleries and oil galleries.
2. Install a NEW cylinder head gasket (3). The marking "Top" should point to the cylinder head.
3. Install the cylinder head (2).
4. Install 12 NEW cylinder head bolts (1) and hand tighten.
5. Lay a straight edge (1) against the engine block and cylinder head. Adjust the transition in area (2) until there is no clearance between cylinder head and straight edge, using a rubber mallet.
6. Tighten the cylinder head bolts in the sequence shown and to the following specifications: Tighten the cylinder head bolts to 35 N.m (26 lb ft). Tighten the cylinder head bolts an additional 180 degrees. Use EN-470-B wrench.

Hydraulic Valve Lash Adjuster Installation

1. Lubricate the hydraulic valve lash adjusters with engine oil.
2. Install the 16 hydraulic valve lash adjusters (1).

Hydraulic Valve Lash Adjuster Arm Installation

1. Lubricate the hydraulic valve lash adjuster arms with engine oil.
2. Install the 16 hydraulic valve lash adjuster arms (1).

Intake Camshaft Installation

1. Lubricate camshaft and camshaft bearing caps with engine oil.
2. Install the intake camshaft (3).
3. Install the 5 camshaft bearing caps (2).
4. Install the 10 camshaft bearing cap bolts (1) and handtighten.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71 lb in).

Exhaust Camshaft Installation

1. Lubricate camshaft and camshaft bearing caps with engine oil.
2. Install the exhaust camshaft (3).
3. Install the 5 camshaft bearing caps (2).
4. Install the 10 camshaft bearing cap bolts (1) and handtighten.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71 lb in).

Camshaft Sprocket Installation

1. Install the intake camshaft sprocket (3).
2. Install the intake camshaft position sensor exciter wheel (2) and the intake camshaft sprocket bolt (1), but do not tighten yet.
3. Install the exhaust camshaft sprocket.
4. Install the exhaust camshaft position sensor exciter wheel and the exhaust camshaft sprocket bolt, but do not tighten yet.

Timing Chain Tensioner Installation

1. Install the timing chain tensioner (2).
2. Install the 2 timing chain tensioner bolts (1) and tighten to 8 N.m (71 lb in).

Engine Front Cover Gasket Installation

1. Clean the sealing surfaces and remove all remains of old sealing compound material.
2. Apply sealing compound to the shown areas (1) and (2). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
3. Install the NEW engine front cover gasket (1).
4. Install the timing chain. Refer to «Camshaft Timing Chain Installation»(ref-542544-S34825258852013041600000) .
5. Install the engine front cover. Refer to «Engine Front Cover and Oil Pump Installation»(ref-542544-S15919767622013041600000) .

Camshaft Timing Chain Installation

Special Tools

1. EN-952 Fixing Pin
2. EN-953-A Fixing Tool
3. EN-955-10 Fixing Pin from EN-955 Kit

For equivalent regional tools, refer to Special Tools .

1. The engine should be adjusted to TDC.
2. The crankshaft should be locked with EN-952 fixing pin.
3. The camshaft should be locked with EN-953-A fixing tool.
4. Install the timing chain (1) along with the crankshaft sprocket (2).
5. Install the timing chain tensioner shoe (1).
6. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).
7. Install the timing chain guide right side (1).
8. Install the 2 timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).
9. Push the timing chain (2) in direction to the timing chain tensioner (1) and remove the EN-955-10 fixing pin (3).

The upper timing chain guide will be installed after the installation of the engine front cover and the fastening of the camshaft sprockets.

Engine Front Cover and Oil Pump Installation

Special Tools

1. EN-952 Fixing Pin
2. EN-953-A Fixing Tool
3. EN-49977-100 Transmitter Disc Fixation
4. EN-49977-200 Fixing Tool

For equivalent regional tools, refer to Special Tools .

1. Install the engine front cover (3).
2. Install the 13 engine front cover bolts M6 (1).
3. Install the 2 engine front cover bolts M10 (2).
4. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).
5. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).

Upper Timing Chain Guide Installation

1. Install the upper timing chain guide (2).
2. Install the 2 upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
3. Remove EN-953-A fixing tool and EN-952 fixing pin.
4. Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 50 N.m (37 lb ft).

Oil Pan Installation

Special Tools

EN-49980 Guidance Pins

For equivalent regional tools, refer to Special Tools .

1. Clean the sealing surfaces from old sealing material, dirt, oil and grease.
2. Apply sealing compound to the oil pan. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
3. Apply sealing compound to the groove of the engine front cover (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
4. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate.
5. Install the 2 EN-49980 pins (1) and (2) to the shown oil pan screw bores.
6. Carefully install the oil pan. Guide the oil pan with EN-49980 pins (2) and the equivalent screw bores (1).
7. Hold the oil pan with 4 oil pan bolts.
8. Remove EN-49980 pins.
9. Install the remaining 12 oil pan bolts and hand tighten.
10. Lay a straight edge (1) against the oil pan and engine block. Using a rubber mallet, adjust the transition in area (2) until there is no clearance between oil pan and the straight edge.
11. Tighten the 16 oil pan bolts to 10 N.m (89 lb in).

Camshaft Position Actuator Solenoid Valve Installation

1. Install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by carefully and evenly pressing.
2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 N.m (71 lb in).
3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2).

Camshaft Cover Installation

1. Clean the sealing surfaces.
2. Apply sealing compound to areas (1) and (2). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-542544-S18132208432013041600000) .
3. Install the camshaft cover (2) and a NEW gasket (3).
4. Install the 15 camshaft cover bolts (1).
5. Tighten the 15 camshaft cover bolts in a sequence as shown to 8 N.m (71 lb in).
6. Install the oil level indicator (1).

Ignition Coil Installation

Special Tools

EN-6009 Remover and Installer Ignition Module

For equivalent regional tools, refer to Special Tools .

1. Install the ignition coil (1) and remove EN-6009 remover and installer (2).
2. Install the 2 ignition coil bolts (1) and tighten to 8 N.m (71 lb in).

Engine Flywheel Installation

Special Tools

1. EN-470-B Angular Torque Wrench
2. EN-652 Flywheel Holder

For equivalent regional tools, refer to Special Tools .

1. Install the engine flywheel (1).
2. Install the 6 NEW engine flywheel bolts (2).
3. Install EN-652 holder (1) to hold the engine flywheel (2).
4. Tighten the 6 engine flywheel bolts in a cross sequence to 60 N.m (44 lb ft). Tighten the 6 engine flywheel bolts in a cross sequence to an additional 45 degrees. Use EN-470-B wrench. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 15 degrees. Use EN-470-B wrench.
5. Remove EN-652 holder.

Generator Installation

1. Install the generator (1).
2. Install the 2 generator bolts (2) and tighten to 35 N.m (26 lb ft).

Starter Installation

1. Install the starter (4).
2. Install the lower starter bolt stud (3) and if equipped the washer.
3. Install the upper starter bolt (2) and if equipped the washer (1).
4. Tighten the starter bolt and starter bolt stud to 25 N.m (18 lb ft).

Intake Manifold Installation

1. Clean the sealing surfaces.
2. Install the intake manifold (1) along with a NEW intake manifold gasket.
3. Install the 6 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).

Throttle Body Installation

1. Install the throttle body (2) and a NEW throttle body seal ring (1).
2. Install the 4 throttle body bolts (3) and tighten to 8 N.m (71 lb in).

Water Pump Installation

1. Clean the sealing surfaces.
2. The water pump and engine front cover bolts are located as followed: Engine front cover special bolt without cone end 60 mm (2.362 in) (1). Engine front cover standard bolt with cone end 52 mm (2.047 in) (2). Water pump bolt 25 mm (0.984 in) (3).
3. Install the water pump (2) and a NEW water pump gasket (1).
4. Install the 5 water pump bolts (4) and the 5 long engine front cover bolts (3) and tighten in a cross sequence to 8 N.m (71 lb in).

Crankshaft Balancer Installation

Special Tools

1. EN-470-B Angular Torque Wrench
2. EN-956-1 Extension
3. EN-49979 Crankshaft Shock Mount Retainer

For equivalent regional tools, refer to Special Tools .

1. Install the crankshaft balancer by carefully pressing into position.
2. Measure the distance a between the crankshaft balancer (2) and the engine front cover (1). The distance a should be 5.5 mm (0.21654 in).
3. Install a NEW crankshaft balancer bolt.
4. Tighten the crankshaft balancer bolt (4) while holding the crankshaft balancer (3) with EN-49979 retainer (1) and EN-956-1 extension (2) in the following order: Tighten the crankshaft balancer bolt to 150 N.m (111 lb ft). Tighten the crankshaft balancer bolt to an additional 60 degrees, using EN-470-B wrench.

Water Pump Pulley Installation

1. Install the water pump pulley (1).
2. Install the 3 water pump pulley bolts (2).
3. Tighten the 3 water pump pulley bolts (2) to 22 N.m (16 lb ft) while holding up the water pump pulley hub with a wrench.

Air Conditioning Compressor Bracket Installation

1. Install the air conditioning compressor bracket (2).
2. Install the 3 air conditioning compressor bracket bolts (1) and tighten to 22 N.m (16 lb ft).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner (1).
2. Install the upper drive belt tensioner bolt (2).
3. Install the lower drive belt tensioner bolt (3).
4. Tighten the lower drive belt tensioner bolt (M8) to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt to 55 N.m (41 lb ft).

Drive Belt Installation

Special Tools

1. EN-955 Locking Pins
2. EN-48488 Holding Wrench

For equivalent regional tools, refer to Special Tools .

1. Install the drive belt.
2. Move the drive belt tensioner clockwise until EN-955-20 locking pin (2) can be removed. Use EN-48488 wrench (1).
3. Remove EN-955-20 locking pin (2) from the drive belt tensioner while holding with EN-48488 wrench (1).
4. Release tension from drive belt tensioner and remove EN-48488 wrench (1).

Engine Oil Cooler Installation

1. Install the engine oil cooler assembly (6) along with 2 NEW sealings (8) and (9).
2. Install the 3 oil cooler bolts (5) and tighten to 10 N.m (89 lb in).
3. Install the oil cooler coolant outlet pipe bolt (7) and tighten to 10 N.m (89 lb in).
4. Install the oil cooler coolant outlet hose (2) to the engine coolant thermostat housing.
5. Install the oil cooler coolant outlet hose clamp (1).
6. Install the oil cooler coolant inlet hose (4) to the water outlet.
7. Install the oil cooler coolant inlet hose clamp (3).

Water Outlet Installation

1. Clean the sealing surfaces.
2. Install the water outlet (2) and a NEW water outlet seal ring (1).
3. Install the 3 water outlet bolts (3) and tighten to 8 N.m (71 lb in).

Engine Coolant Thermostat Housing Installation

1. Clean the sealing surfaces.
2. Install the engine coolant thermostat housing (2) and a NEW engine coolant thermostat housing seal ring (3).
3. Install the 3 engine coolant thermostat housing bolts (1) and tighten to 8 N.m (71 lb in).

Turbocharger Installation

Special Tool

EN-49942 Holding Wrench

For equivalent regional tools, refer to Special Tools .

1. Clean the sealing surfaces.
2. Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return pipe. Refer to «Turbocharger Disassemble»(ref-542544-S17114921312013041600000) , and «Turbocharger Assemble»(ref-542544-S02108635212013041600000) .
3. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).
4. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
5. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).
6. Install the 8 NEW turbocharger nuts (1).
7. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).
8. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.
9. Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe bolt to 8 N.m (71 lb in).
10. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
11. Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
12. Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to 10 N.m (89 lb in).
13. Tighten the turbocharger oil feed pipe hollow screw to 30 N.m (22 lb ft).
14. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
15. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m (22 lb ft).

Exhaust Manifold Heat Shield Installation

1. Install the exhaust manifold heat shield (2).
2. Install the 3 exhaust manifold heat shield bolts (1) and the washers and tighten to 8 N.m (71 lb in).

Warm Up Three-Way Catalytic Converter Installation

1. Install the warm up three way catalytic converter (5) to the brackets and the turbocharger. Use a NEW warm up three way catalytic converter seal (2).
2. Install a NEW warm up three way catalytic converter V-clamp (1).
3. Install the 2 catalytic converter to catalytic converter bracket nuts (4) and (6) and hand tighten.
4. Hand tighten the catalytic converter V-clamp.
5. Connect the heated oxygen sensor wiring harness (3) to retainer clip.
6. The catalytic converter V-clamp (1) should be installed in the shown position.
7. Tighten the catalytic converter to catalytic converter bracket nuts to 22 N.m (16 lb ft).
8. Tighten the catalytic converter V-clamp to 13 N.m (115 lb in).

Positive Crankcase Ventilation Pipe Installation

1. Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
2. Connect the positive crankcase ventilation pipe to turbocharger (3).
3. Install the charger air bypass valve pipe (2) to turbo charger waste regulator solenoid valve.
4. Install the charger air bypass valve pipe to turbocharger.
5. Fasten the charger air bypass valve pipe clamp (4).
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).

Engine Mount Bracket Installation

1. Install the engine mount bracket (2).
2. Install the 3 engine mount bracket bolts and tighten to 60 N.m (45 lb ft) + 45-60°.

Oil Pump Installation

1. Install the oil pump components in the following order: NOTE: The bore (8) in the oil pump slide must fit smooth-running and without clearance to the oil pump slide pivot pin (7). Install the oil pump slide (6). Install the inner oil pump vane ring (5). NOTE: Mind the installation position of the oil pump vane rotor (4). The mark (9) must point to direction of the oil pump cover. Install the oil pump vane rotor (4). NOTE: Mind the localized flats (3) on the oil pump vanes (2) caused by the oil pump vane rings. The localized flats must point to the oil pump vane rotor. Install the 6 oil pump vanes (2). Install the outer oil pump vane ring (1).
2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2 grooves (1) of the oil pump slide.
3. Protect the engine front cover edge (5) with a suitable piece of plastic.
4. Install the oil pump slide spring pin along with the oil pump slide spring (4). Use a screwdriver to compress the oil pump slide spring. The flat side of oil pump slide spring pin must face upwards.
5. Measure the oil pump clearances to ensure a correct installation of the oil pump components. Refer to «Engine Front Cover and Oil Pump Cleaning and Inspection»(ref-542544-S00028493962013041600000) .
6. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the area (3) with engine oil.
7. Inspect the oil pump slide spring mechanism for functionality.
8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).
9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).
10. Install the crankshaft balancer (1) and rotate in the direction shown (2) in order to inspect the function of the oil pump mechanism. The crankshaft balancer should rotate easily.

Drive Belt Removal

Special Tools

1. EN-955 Locking Pins
2. EN-48488 Holding Wrench

For equivalent regional tools, refer to Special Tools .

1. Install EN-48488 wrench (1) to the drive belt tensioner.
2. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with the EN-955-20 locking pin (2).
3. Remove the drive belt.