Overhaul - 3.8L Engine: Removal & Installation Chrysler Pacifica CS

INSTALLATION - ENGINE ASSEMBLY

Scheme 246

1. Position engine and transmission assembly under vehicle. Slowly lower the vehicle down over the engine and transmission until the cradle is aligned.
2. Install the cradle supporting bolts and tighten to 163 N.m (120 ft.lbs.). see scheme 10
3. Install the right engine mount. tighten the bolts to the timing cover to 54 N.m (40 ft.lbs.), tighten the bolts to the right rail to 68 N.m (50 ft.lbs.). see scheme 15 1 - BOLT 2 - MOUNT BRACKET 3 - ENGINE RIGHT MOUNT ASSEMBLY
4. Slowly raise the vehicle off of the cradle support. 1 - STRUT 2 - BRACKET
5. Install the rear transmission torque strut and tighten bolts to 54 N.m (40 ft. lbs.). see scheme 16
6. Install the engine wiring harness ground strap to transmission case.
7. Connect the left front strut to steering knuckle. Tighten bolts to 81 N.m (60 ft. lbs.) plus 90 degrees.
8. Connect the left stabilizer link. Tighten to 88N.m (65 ft.lbs.). 1 - STRUT ASSEMBLY 2 - SCREW 3 - WHEEL SPEED SENSOR ROUTING BRACKET
9. Connect the left wheel speed sensor and harness push pin. (Scheme 246) 1 - LOWER STEERING COLUMN COUPLING ASSEMBLY 2 - INTERMEDIATE SHAFT TO STEERING GEAR 3 - PIN 4 - STEERING GEAR 5 - EXTENSION TO SHAFT BOLT
10. Reconnect the steering column intermediate shaft to the steering gear. see scheme 18
11. Connect the right front strut to steering knuckle. Tighten bolts to 81 N.m (60 ft. lbs.) plus 90 degrees. see scheme 10
12. Connect the right stabilizer link. Tighten to 88N.m (65 ft.lbs.). see scheme 10
13. Connect the right wheel speed sensor and harness push pin. (Scheme 246)
14. Install wheels.
15. Connect the in block heater (if equipped).
16. Connect the knock sensor electrical connector.
17. Install the exhaust system and connect the O2 sensor.
18. Install the torque converter bolts. Tighten the bolts to 88N.m (65 ft.lbs.).
19. Install the flex plate inspection cover.
20. Connect the starter wiring, route harness and secure with push pin.
21. Install the front fascia.
22. Connect the coolant hose at the engine oil cooler.
23. Connect the oil pressure sending unit (OPS) wiring harness connector.
24. Lower the vehicle.
25. Connect the A/C lines and compressor electrical connector. (Refer to «A/C COMPRESSOR»(ref-245452-S40123653532006110200000).
26. Route the engine harness to the left cylinder head and attach the purge solenoid.
27. Connect the engine sensor wiring harness connectors.
28. Connect the engine vacuum harnesses.
29. Connect the fuel line to the fuel rail.
30. Connect the generator electrical connectors «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-245457-S32388919322006110200000). 1 - SOLENOID PACK CONNECTOR 2 - INPUT SPEED SENSOR CONNECTOR 3 - OUTPUT SPEED SENSOR CONNECTOR 4 - TRANSMISSION RANGE SENSOR CONNECTOR
31. Connect the transmission controller, sensor electrical connectors and fluid lines. see scheme 19
32. Connect the radiator, coolant reservoir and heater hoses. 1 - THROTTLE BODY 2 - SPEED CONTROL CABLE ACCESS 3 - THROTTLE CABLE
33. Connect the throttle and cruise control cables. see scheme 20
34. Install the air cleaner housing and connect the CCV hose to the left cylinder head cover (Refer to «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) ).
35. Fill the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
36. Evacuate and recharge A/C system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) and «REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) ).
37. Install new oil filter. Fill engine crankcase with proper oil to correct level «(Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - SPECIFICATIONS)»(ref-245418-S29161845372006110200000).
38. Connect negative cable to battery.
39. Fill the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
40. Bleed the braking system (Refer to «STANDARD PROCEDURE - BASE BRAKE BLEEDING»(ref-245442-S22738222762006110200000) ).
41. Start engine and run until operating temperature is reached.

INSTALLATION

1. Install the air filter element into air box. see scheme 46
2. Move cover so that the tabs insert into the air cleaner housing. 1 - INTAKE AIR TEMPERATURE SENSOR 2 - CRANK CASE VENTILATION HOSE 3 - BOLT
3. Position the cover down over the element and lower housing and tighten the fasteners. see scheme 47
4. Connect the air inlet tube to the throttle body and tighten the clamp.
5. Connect the IAT sensor. see scheme 47
6. Connect the CCV hose. see scheme 47

REMOVAL

1. Disconnect the negative battery cable.
2. Disconnect the inlet air temperature sensor. see scheme 48
3. Disconnect the CCV hose from the air cleaner cover. see scheme 48
4. Remove the air inlet tube to throttle body. see scheme 48
5. Remove the bolt for air cleaner housing at upper radiator cross member. see scheme 48
6. Pull air box up and off over the single locating pin.
7. Remove air box from vehicle.

1. Install air cleaner housing into vehicle and onto the locating pin.
2. Install bolt to hold air cleaner housing to the upper radiator cross member. see scheme 49
3. Install the air inlet tube to the throttle body and tighten clamp. see scheme 49
4. Connect the IAT sensor. see scheme 49
5. Connect the CCV hose to the air cleaner cover. see scheme 49
6. Connect the negative battery cable.

Scheme 247

The aluminum cylinder heads. (Scheme 247)are designed to create high flow combustion chambers to improve performance, while minimizing the change to the burn rate in the chamber. The cylinder head incorporates the combustion chamber. Two valves per-cylinder are used with inserted valve seats and guides. A multi-layer steel (MLS) type gasket is used between the cylinder head and engine block.

1. Disconnect spark plug wires from spark plugs.
2. Disconnect crankcase vent hose from cylinder head cover.
3. Remove cylinder head cover bolts.
4. Remove cylinder head cover and gasket.

1. Clean cylinder head and cylinder head cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary.
2. Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket. see scheme 58
3. Install the cylinder head cover and bolts.
4. Tighten cylinder head cover bolts to 12 N.m (105 in. lbs.). see scheme 60
5. Connect crankcase vent hose.
6. Connect spark plug wires to spark plugs.

Scheme 248

1. Coat valve stems with clean engine oil and insert them in cylinder head. see scheme 70
2. Install valve spring seat on head. see scheme 70
3. Install new seals on all valve stems and over valve guides Install valve springs and valve retainers. (Scheme 248)
4. Install the valve springs. (Refer to «VALVE SPRINGS»(ref-245455-S02370150062006110200000) )

Scheme 249

There are two interchangeable, floating (spring rotates during operation), valve spring designs. Type A may be identified by the counterclockwise (spring spirals down and to the left) appearance, And Type B may be identified by the clockwise (spring spirals down and to the right) appearance. Both of the valve springs are a bee-hive shaped design but have different specifications. (Scheme 249)

Scheme 250

The springs are seated on a steel washer on the cylinder head with retainers and locks retaining the springs. (Scheme 250) The springs are installed with the smaller diameter against spring retainer. (Scheme 249)

REMOVAL - CYLINDER HEAD OFF

1. With the cylinder head on a bench, position Special Tool C-3422-D with 8464 Adapter on the valve and spring retainer. see scheme 74
2. Compress the spring only enough to remove the valve retainer locks.
3. Slowly release the spring tension and remove the valve spring and retainer.
4. For removal of the valve stem seal (Refer to «VALVE STEM SEALS»(ref-245455-S33105943752006110200000) ).

Scheme 251

1. Disconnect negative cable from battery.
2. Remove spark plug wires and all spark plugs.
3. Remove cylinder head cover(s). (Refer to «CYLINDER HEAD COVER(S)»(ref-245455-S28149962872006110200000) )
4. Remove rocker arms and shaft. «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS - REMOVAL)»(ref-245455-S14436017312006110200000)
5. Rotate engine until the piston in the cylinder bore requiring spring removal is at TDC.
6. Install Special Tool 8453 to the cylinder head. (Scheme 251) Tighten the attaching bolts to 23 N.m (200 in. lbs.).
7. Install a spark plug adapter in the spark plug hole. Connect air hose that can supply 620.5-689 kPa (90-100 psi) of air pressure to adapter. This is to hold valves in place while servicing components.
8. Locate the forcing screw and spring retainer adapter assembly over the spring requiring removal. (Scheme 251)
9. Slowly turn the forcing screw clockwise (compressing the valve spring) until the valve keepers can be removed.
10. Turn forcing screw counterclockwise to relieve spring tension. Remove retainer and valve spring.
11. Repeat procedure for each cylinder requiring valve spring removal.

Scheme 252

Note. The are two different types of valve springs used that are interchangable, but have different specifications (Refer to DESCRIPTION ).

Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. (Scheme 252) As an example; the compression length of a spring to be tested is 38.00 mm (1.496 in.). Turn the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 in.) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to SPECIFICATIONS to obtain specified height and allowable tensions (Refer to SPECIFICATIONS ). Replace any springs that do not meet specifications.

INSTALLATION - CYLINDER HEAD OFF

Scheme 253

1. If removed, install a new valve stem seal (Refer to «VALVE STEM SEALS»(ref-245455-S33105943752006110200000) ).
2. Position valve spring and retainer on spring seat.
3. Using Special Tool C-3422-D with 8464 Adapter. see scheme 77, compress the spring only enough to install the valve retainer locks. Install valve retainer locks. 1 - VALVE SPRING RETAINER 2 - VALVE INSTALLED HEIGHT 3 - CYLINDER HEAD SURFACE 4 - VALVE SPRING SEAT SURFACE 5 - VALVE SPRING INSTALLED HEIGHT
4. Slowly release the spring tension. Ensure the retainer locks are seated properly. (Scheme 253)

INSTALLATION - CYLINDER HEAD ON

1. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. see scheme 79 CAUTION: Do not pinch seal between retainer and top of valve guide.
2. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered.
3. Remove spark plug adapter tool.
4. Install rocker arms and shaft assembly. «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS - INSTALLATION)»(ref-245455-S22966749832006110200000)
5. Install cylinder head covers. (Refer to «CYLINDER HEAD COVER(S)»(ref-245455-S28149962872006110200000) )
6. Install spark plugs and connect wires.
7. Connect negative cable to battery.

1. Remove the valve springs. (Refer to «VALVE SPRINGS»(ref-245455-S02370150062006110200000) )
2. Remove the valve stem seal. see scheme 84

1. Install the valve stem seal squarely over the valve guide, using the valve stem as a guide. see scheme 84 Do not force the seal against top of the valve guide.
2. Install the valve spring. (Refer to «VALVE SPRINGS»(ref-245455-S02370150062006110200000) )

Note. Refer to the connecting rod Description before beginning repair. (Refer to DESCRIPTION ).

Scheme 254

Scheme 255

1. Disconnect negative cable from battery.
2. Remove the cylinder heads. (Refer to «CYLINDER HEAD»(ref-245455-S11415369272006110200000) )
3. Remove the oil pan. (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) )
4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore.
5. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe, if necessary. (Scheme 254) 1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN REMOVING OR INSTALLING PISTON ASSEMBLY
6. Remove connecting rod cap. Install connecting rod bolt protectors. (Scheme 255) on connecting rod bolts or use special tool #8189 to guide cracked connecting rod.
7. Remove each piston and connecting rod assembly out of the cylinder bore. NOTE: Be careful not to nick crankshaft journals.
8. After removal, install bearing cap on the mating rod.

Note. Refer to the connecting rod Description before beginning repair. (Refer to DESCRIPTION ).

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

1. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. (Scheme 256)and that the arrow on top of the piston is facing the front of the engine, if equipped. (Scheme 257)
2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located (Scheme 256) 1 - RING - OIL CONTROL 7 - CAP - CONNECTING ROD 2 - RING - NO. 2 COMPRESSION 8 - BEARING - CONNECTING ROD LOWER 3 - RING - NO. 1 COMPRESSION 9 - CRANKSHAFT JOURNAL PROTECTOR (RUBBER HOSE) 4 - RING - SIDE RAIL UPPER & LOWER 10 - BEARING - CONNECTING ROD UPPER 5 - PISTON RING COMPRESSOR 11 - PISTON AND CONNECTING ROD ASSEMBLY 6 - NUT - CONNECTING ROD 12 - PISTON LOCATION MARK (F = FRONT)
3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. (Scheme 258) Be sure position of rings does not change during this operation.
4. Position upper bearing onto connecting rod. Lubricate bearing with oil. 1 - "F" TOWARD FRONT OF ENGINE 2 - RING COMPRESSOR 3 - SPECIAL TOOL 8189 4 - OIL SQUIRT HOLE
5. Install connecting rod bolt protectors (rubber hose or equivalent). (Scheme 258) on the connecting rod bolts, or use special tool. (Scheme 259)#8189 for cracked cap design 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE
6. The pistons are marked with a "F" located near the piston pin, or an arrow on top of the piston. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block. (Scheme 260)
7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore by tapping down on the piston using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (Scheme 258)
8. Install lower bearing shell and the appropriate connecting rod cap. (Scheme 258)
9. Install connecting rod cap retaining nuts on cleaned and oiled rod bolts and tighten to 54 N.m (40 ft. lbs.) PLUS 1/4 turn. Install connecting rod bolts and tighten to 7 N.m (5 ft. lbs) initially. Tighten the bolts an additional 21 N.m (15 ft. lbs.) and then turn each bolt 90° to final clamping load.
10. Repeat procedure for each piston and connecting rod installation.
11. Install the cylinder heads. (Refer to «CYLINDER HEAD»(ref-245455-S11415369272006110200000) )
12. Install the oil pan. (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) )
13. Fill engine crankcase with proper oil to correct level.
14. Connect negative cable to battery.

Scheme 261

Either style of bearing cap is not interchangeable and should be marked at removal to ensure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Fit all rods on one bank until complete. Connecting rod bearings are available in the standard size and the following undersizes: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.).

Measure connecting rod journal for taper and out-of-round. (Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT - INSPECTION)

The connecting rod bearing clearances can be determined by use of Plastigage or the equivalent. The following is the recommended procedure for the use of Plastigage

1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke.
2. Remove oil film from surface to be checked. Plastigage is soluble in oil.
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 in.) off center and away from the oil hole. In addition, suspect areas can be checked by placing Plastigage in that area.
4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results.
5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. (Scheme 261) Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to «SPECIFICATIONS»(ref-245455-S08864132092006110200000) (Refer to «SPECIAL TOOLS»(ref-245455-S42758410712006110200000) ). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds wear limit specification, replace the bearing.

Scheme 262

1. Wipe cylinder bore clean. Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm (0.50 in.) from top of cylinder bore. Check ring gap with a feeler gauge. (Scheme 262) For clearance specification (Refer to «SPECIFICATIONS»(ref-245455-S08864132092006110200000) ). 1 - FEELER GAUGE
2. Check piston ring to groove side clearance. (Scheme 263) For clearance specification (Refer to «SPECIFICATIONS»(ref-245455-S08864132092006110200000) )

Scheme 263

Scheme 264

1. Remove piston and connecting rod. (Refer to «PISTON & CONNECTING ROD»(ref-245455-S26285510652006110200000) )
2. Remove No. 1 and No.2 piston rings from piston using a ring expander tool. (Scheme 264)
3. Remove upper oil ring side rail.
4. Remove lower oil ring side rail.
5. Remove oil ring expander.

Scheme 265

Scheme 266

1. Install rings with manufacturers I.D. mark (if present) facing up, to the top of the piston. (Scheme 265) CAUTION: Install piston rings in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring. 1 - NO. 1 PISTON RING 2 - NO. 2 PISTON RING 3 - SIDE RAIL 4 - OIL RING 5 - SPACER EXPANDER
2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. (Scheme 266)
3. Install upper side rail first and then the lower side rail. 1 - SIDE RAIL END
4. Install No. 2 piston ring and then No. 1 piston ring. see scheme 112
5. Position piston ring end gaps (Scheme 267)
6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Scheme 267

1. Position new gasket and install retainer on block. see scheme 130 Tighten attaching screws to 12 N.m (105 in. lbs.).
2. Install oil pan (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) ).
3. Install oil seal (Refer to «CRANKSHAFT OIL SEAL - REAR»(ref-245455-S05616997632006110200000) ).

Scheme 268

1. Disconnect negative cable from battery.
2. Raise vehicle on hoist.
3. Remove the right front wheel and inner splash shield.
4. Remove the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-245448-S38168346922006110200000)
5. Remove vibration damper bolt.
6. Insert Special Tool 8450 into crankshaft nose. (Scheme 268)
7. Position 3-jaw puller Special Tool 1026 on damper (Scheme 268) Turn puller forcing screw until damper releases from crankshaft.
8. Remove the crankshaft vibration damper.

Scheme 269

1. Install crankshaft vibration damper using the forcing screw, nut, and thrust bearing/washer from Special Tool 8452. (Scheme 269) NOTE: To minimize friction and prolong tool life, lubricate the threads on the forcing screw of Special Tool 8452.
2. Position vibration damper on crankshaft.
3. Screw Special Tool 8452 into crankshaft until the bolt seats. Turn the nut to install damper until it seats fully.
4. Remove Special Tool 8452.
5. Install vibration damper bolt. Torque bolt to 54 N.m (40 ft. lbs.).
6. Install the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-245448-S15036353902006110200000)
7. Install inner splash shield and right front wheel.
8. Connect negative cable to battery.

Scheme 270

1. Remove the transmission «(Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE - REMOVAL)»(ref-245428-S38177214452006110200000).
2. Remove flex plate attaching bolts.
3. Remove the flex plate. (Scheme 270)

1. Position flex plate with backing plate on the crankshaft. (Scheme 270)
2. Apply Mopar® Lock & Seal Adhesive to the flex plate bolts.
3. Install flex plate bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
4. Install the transmission «(Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE - INSTALLATION)»(ref-245428-S02146376792006110200000).

INSTALLATION - UPPER ENGINE MOUNT

1. Install engine bracket (if removed). Tighten bolts to 33 N.m (24 ft. lbs.).
2. Position the upper engine mount and install frame rail to mount bolts. see scheme 135 Tighten bolts to 68 N.m (50 ft. lbs.).
3. Install the mount to engine bracket bolts and tighten to 54 N.m (40 ft. lbs.). see scheme 135
4. Remove jack from under engine.
5. Install air cleaner housing and element.

Scheme 271

1. Disconnect the negative battery cable.
2. Remove the cruise control servo and position servo aside.
3. Remove the radiator fan assembly «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-245448-S13296076712006110200000).
4. Remove the left exhaust manifold (Refer to «EXHAUST MANIFOLD - LEFT»(ref-245455-S00717085992006110200000) ).
5. Remove the starter «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)»(ref-245458-S07324738642006110200000).
6. Raise and support the vehicle.
7. Remove the lower engine bracket mount fasteners from the engine.
8. Remove the engine mount to cradle fastener.
9. Lower the vehicle.
10. Support the engine with a floor jack.
11. Remove the upper engine mount bracket to engine block fasteners and remove engine mount. (Scheme 271)
12. Separate the engine mount from the bracket.

Scheme 272

1. Align engine mount to bracket and tighten upper engine mount fastener to 101 N.m (75 ft.lbs.). (Scheme 272) 1 - UPPER ENGINE MOUNT BRACKET FASTENER 2 - ENGINE MOUNT BRACKET 3 - ENGINE MOUNT 4 - ENGINE MOUNT FASTENER
2. Install the engine mount with bracket into position and hand tighten the upper engine mount bracket fasteners. see scheme 138
3. Raise and support the vehicle.
4. Install the left engine mount bracket lower fasteners. Tighten the fasteners to 68 N.m (50 ft.lbs.).
5. Remove the jackstand.
6. Install the engine mount to cradle fastener. Tighten the fastener to 101 N.m (75 ft.lbs.).
7. Lower the vehicle.
8. Tighten the upper engine mount bracket fasteners to 101 N.m (75 ft.lbs.).
9. Install the starter «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)»(ref-245458-S24709956922006110200000).
10. Install the left exhaust manifold (Refer to «EXHAUST MANIFOLD - LEFT»(ref-245455-S00717085992006110200000) ).
11. Install the radiator fan assembly «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-245448-S13225941362006110200000).
12. Install the cruise control servo.
13. Reconnect the negative battery cable.

Scheme 273

Scheme 274

1. Disconnect the negative battery cable.
2. Raise vehicle on hoist. 1 - CRANKSHAFT SENSOR 2 - BRACKET 3 - HEAT SHIELD 4 - EXHAUST
3. Remove the right mount heat shield. (Scheme 273)
4. Remove the push pins for the in block heater (if equipped), the crankshaft sensor and the oxygen sensor from the engine mount bracket.
5. Support the engine with a jack stand.
6. Remove the engine mount bracket fasteners from the transaxle. (Scheme 274)
7. Remove the right engine mount to cradle fastener. (Scheme 274)
8. Loosen the front engine mount to cradle fastener.
9. Raise and support the engine with the jack stand. 1 - DRIVE AXLE 2 - BRACKET 3 - ENGINE MOUNT
10. Remove the engine mount. (Scheme 274)
11. Separate the engine mount from bracket.

INSTALLATION - RIGHT ENGINE MOUNT

1. Align and Install mount bracket, if removed. Tighten top engine mount fastener to 101N.m (75 ft.lbs.). see scheme 141 1 - DRIVE AXLE 2 - BRACKET 3 - ENGINE MOUNT
2. Install the right mount, bracket and bolts. see scheme 142 Tighten bolts to 101 N.m (75 ft. lbs.).
3. Lower the engine and remove the jack stand.
4. Install the engine mount to cradle fastener. see scheme 141 Tighten both engine mount to cradle fasteners to 101 N.m (75 ft. lbs.). 1 - CRANKSHAFT SENSOR 2 - BRACKET 3 - HEAT SHIELD 4 - EXHAUST
5. Install the right mount heat shield. see scheme 143

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Support the transmission with a floor jack.
4. Remove the torque strut. see scheme 144

1. Install the torque strut. see scheme 145 Tighten the fasteners to 54 N.m (40 ft.lbs.).
2. Remove the floor jack
3. Lower the vehicle.
4. Reconnect the negative battery cable.

1. Lubricate seal and position oil cooler to connector fitting on oil filter adapter. see scheme 152 NOTE: Position the flat side of oil cooler parallel to oil pan rail.
2. Install oil cooler attachment fitting and tighten to 27 N.m (20 ft. lbs.). see scheme 152
3. Install oil filter. 1 - OIL COOLER INLET TUBE 2 - INLET HOSE 3 - OIL COOLER OUTLET TUBE 4 - OUTLET HOSE 5 - WATER PUMP INLET TUBE
4. Connect oil cooler inlet and outlet hoses. see scheme 153
5. Fill cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM FILLING)»(ref-245448-S20805593812006110200000).

1. Using suitable oil filter wrench, turn filter counterclockwise to remove from oil filter adapter. see scheme 154 Properly discard used oil filter.

1. Wipe oil filter adapter base clean and inspect gasket contact surface.
2. Lubricate gasket of new filter with clean engine oil.
3. Install new filter until gasket contacts base. see scheme 154 Tighten filter 1 turn or 20 N.m (15 ft. lbs.). Use filter wrench if necessary.
4. Start engine and check for leaks.

Scheme 275

1. Raise vehicle on hoist.
2. Remove the oil filter.
3. Disconnect oil pressure switch electrical connector.
4. Remove oil filter adapter attaching bolts. (Scheme 275)
5. Remove oil filter adapter and seal. (Scheme 275)

1. Clean oil filter adapter and install new seal.
2. Position adapter on engine block and install bolts. (Scheme 275)
3. Tighten adapter bolts to 28 N.m (250 in. lbs.).
4. Connect oil pressure switch electrical connector. (Scheme 275)
5. Install the oil filter.
6. Lower vehicle on hoist.
7. Start engine and allow to run approximately 2 minutes.
8. Turn off engine and check oil level. Adjust oil level as necessary.

Scheme 276

Scheme 277

Scheme 278

1. Disconnect negative cable from battery and remove engine oil level indicator tube. (Scheme 276)
2. Raise vehicle on hoist and drain engine oil. 1 - CRANKSHAFT SENSOR 2 - BRACKET 3 - HEAT SHIELD 4 - EXHAUST
3. Remove the right engine mount heat shield. see scheme 157
4. Disconnect the in block heater (if equipped). see scheme 157 1 - FLEX PLATE INSPECTION COVER 2 - RIGHT ENGINE MOUNT BRACKETING
5. Remove the right engine mount structural bracket at the engine and transaxle. (Scheme 277)
6. Remove the flex plate inspection cover. (Scheme 277) 1 - ENGINE BLOCK 2 - BOLT 3 - NUT 4 - OIL PAN 5 - BOLT 6 - GASKET
7. Remove oil pan fasteners. see scheme 161
8. Remove the oil pan and gasket. see scheme 161

1. Clean relief valve, spring and bore. NOTE: Lubricate relief valve with clean engine oil before installing.
2. Install relief valve and spring into housing.
3. Install new retainer cap until flush with sealing surface.
4. Install oil pan (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) ).
5. Fill crankcase with proper oil to correct level.

1. Install oil pressure switch. Torque oil pressure switch to 23 N.m (200 in. lbs.). see scheme 166
2. Connect electrical connector to switch.
3. Lower the vehicle.
4. Start engine and check for leaks.
5. Check engine oil level. Adjust as necessary.

The oil pump is contained within the timing chain cover housing.

1. Remove oil pan. (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) )
2. Remove the timing chain cover. (Refer to «TIMING CHAIN COVER»(ref-245455-S23497034262006110200000) )
3. Disassemble oil pump from timing chain cover. (Refer to «DISASSEMBLY»(ref-245455-S01942099032006110200000) )
4. Clean and Inspect oil pump components. (Refer to «CLEANING»(ref-245455-S26605031032006110200000) ) (Refer to «INSPECTION»(ref-245455-S13666635022006110200000) ).

Scheme 279

1. Remove oil pump cover screws, and lift off cover. (Scheme 279)
2. Remove oil pump rotors. (Scheme 279)
3. Clean and inspect oil pump components. (Refer to «CLEANING»(ref-245455-S26605031032006110200000) ) (Refer to «INSPECTION»(ref-245455-S13666635022006110200000) ).

1. Install oil pump. (Refer to «OIL PUMP»(ref-245455-S24398896522006110200000) )
2. Install timing chain cover (Refer to «TIMING CHAIN COVER»(ref-245455-S23497034262006110200000) ) and oil pan (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) ).

1. Position exhaust manifold on cylinder head. see scheme 195 Install bolts to center runner (cylinder #4) and initial tighten to 2.8 N.m (25 in. lbs.). 1 - CROSS-OVER PIPE 2 - BOLT 3 - GASKET 4 - FLAG NUT
2. Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 N.m (30 ft. lbs.). see scheme 196 NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended.
3. Position heat shield on manifold. see scheme 195
4. Install the remaining manifold attaching bolts. Tighten all bolts to 23 N.m (200 in. lbs.).
5. Install and tighten heat shield attaching nut to 12 N.m (105 in. lbs.). see scheme 195
6. Connect battery negative cable.

Scheme 280

1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. NOTE: DO NOT USE SEALER ON COVER GASKET
2. Position new gasket on timing cover. see scheme 202 Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is 0.5 mm (0.020 in.) beyond the lower edge of the cover. 1 - GASKET 2 - TIMING CHAIN COVER
3. Rotate crankshaft so that the oil pump drive flats are in the vertical position.
4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats. see scheme 202 CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.
5. Install timing cover. see scheme 202
6. Install timing chain cover bolts. Tighten M8 bolts to 27 N.m (20 ft. lbs.) and M10 bolts to 54 N.m (40 ft. lbs.). (Scheme 280) 1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80 2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45 3 - BOLT - M10 x 1.5 x 85
7. Install crankshaft front oil seal. (Refer to «CRANKSHAFT OIL SEAL - FRONT»(ref-245455-S19625380882006110200000) )
8. Install crankshaft vibration damper. (Refer to «VIBRATION DAMPER»(ref-245455-S37642360902006110200000) ) 1 - FLOW TO OIL COOLER 2 - FLOW TO RADIATOR 3 - PIPE 4 - FLOW FROM WATER PUMP
9. Install the coolant cross over pipe. see scheme 204
10. Install A/C compressor.
11. Position and install the power steering line hold downs at the cradle and A/C bracket.
12. Connect the coolant hoses to the coolant cross over pipe.
13. Install the inner fender splash shield.
14. Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 N.m (250 in. lbs.).
15. Install the oil pan (Refer to «OIL PAN»(ref-245455-S10377059062006110200000) ).
16. Lower the vehicle. 1 - POWER STEERING 2 - GENERATOR 3 - ENGINE OIL COOLER 4 - AIR CONDITIONING COMPRESSOR 5 - IDLER PULLEY 6 - BELT TENSIONER 7 - CRANKSHAFT DAMPER 8 - WATER PUMP
17. Install water pump and pulley. «(Refer to COOLING/ENGINE/WATER PUMP - INSTALLATION)»(ref-245448-S37411238372006110200000)
18. Install camshaft position sensor «(Refer to ELECTRICAL/IGNITION CONTROL/CAMSHAFT POSITION SENSOR - INSTALLATION)»(ref-245456-S23143870982006110200000).
19. Connect the A/C electrical connector and the suction, discharge hoses. see scheme 205
20. Install the oil level indicator tube.
21. Install the generator. see scheme 205
22. Install the power steering pump. see scheme 205
23. Install the idler pulley. see scheme 205
24. Install the accessory drive belt. see scheme 205
25. Install the upper engine mount (Refer to «RIGHT MOUNT»(ref-245455-S18707758242006110200000) ).
26. Fill crankcase with engine oil to proper level.
27. Fill cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000)
28. Evacuate and recharge A/C.
29. Check and refill all fluid levels.
30. Connect negative cable to battery.

REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET

1. Disconnect negative cable from battery.
2. Remove the timing chain cover. (Refer to «TIMING CHAIN COVER»(ref-245455-S23497034262006110200000) )
3. Rotate engine by turning crankshaft until the timing marks are aligned (Scheme 281)
4. Remove camshaft sprocket attaching bolt.
5. Remove the timing chain with camshaft sprocket.
6. Remove the crankshaft sprocket. (Refer to «REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-245455-S22923268532006110200000) )

Scheme 281

REMOVAL - CRANKSHAFT SPROCKET

1. Remove the timing chain. (Refer to «REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-245455-S22923268532006110200000) )
2. Using Special Tools 8539, 5048-6, and 5048-1, remove the crankshaft sprocket while holding the crankshaft from turning. (Scheme 282) Be careful not to damage the crankshaft surfaces.

Scheme 282

Scheme 283

1. Position the sprocket on the crankshaft (timing mark out) with the timing slot aligned with the timing pin.
2. Install sprocket using Special Tool 8452. (Scheme 283) Install sprocket until it is fully seats on the crankshaft. 1 - SPECIAL TOOL 8452-3 2 - SPECIAL TOOL 8452-1 3 - CRANKSHAFT SPROCKET 4 - THRUST BEARING / WASHER
3. Install the timing chain and camshaft sprocket. (Refer to «INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-245455-S07846633722006110200000) )

INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET

1. Rotate crankshaft so the timing arrow is to the 12 o'clock position. (Scheme 281) NOTE: Lubricate timing chain and sprockets with clean engine oil before installation.
2. While holding camshaft sprocket and chain in hand, place timing chain around the sprocket, aligning the plated link with the dot on the sprocket. Position the timing arrow to the 6 o'clock position. (Scheme 281)
3. Place timing chain around crankshaft sprocket with the plated link lined up with the dot on the sprocket. Install camshaft sprocket into position.
4. Use a straight edge to check alignment of timing marks.
5. Install camshaft sprocket bolt and washer. Tighten bolt to 54 N.m (40 ft. lbs.).
6. Rotate crankshaft 2 revolutions and check timing mark alignment. (Scheme 281) If timing marks do not line up, remove camshaft sprocket and realign.
7. Install the timing chain cover. (Refer to «TIMING CHAIN COVER»(ref-245455-S23497034262006110200000) )
8. Connect negative cable to battery.