Engine Mechanical - 2.0L Gtdi: Overhaul Ford Edge I рестайлинг

Disassembly

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

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

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

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1. Remove the 2 bolts and the LH and RH engine lift eyes.
2. Remove the 3 bolts and the coolant outlet and gasket.
3. Remove and discard the CHT sensor.
4. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring. Inspect the valve springs. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .
5. Remove and discard the valve seal. Position the Valve Stem Oil Seal Remover and Slide Hammer over the seal. Pull up on the Slide Hammer and Valve Stem Oil Seal Remover and remove the seal.
6. Remove the valves. Inspect the valves. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .

Scheme 2102

Scheme 2103

1. Coat the valve stems with clean engine oil and install the valves.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. Install the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
4. Install a new CHT sensor. Tighten to 11 Nm (97 lb-in).
5. Inspect the gasket and replace if necessary.
6. Install the gasket, coolant outlet and the 3 bolts. Tighten to 10 Nm (89 lb-in).
7. Install the LH and RH engine lift eyes and the 2 bolts. Tighten to 47 Nm (35 lb-ft).

Note. If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod reassembly.

Scheme 2104

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Scheme 2106

1. Remove and discard the piston rings.
2. Remove and discard the 2 piston pin retainers. Remove the piston pin.
3. Separate the piston from the connecting rod. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-494566) .

Scheme 2107

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Scheme 2109

1. Align the piston-to-connecting rod orientation marks and position the piston on the connecting rod.
2. Install the piston pin in the piston and connecting rod assembly.
3. Install the 2 new piston pin retainers in the piston.
4. Install the piston rings on the piston.
5. Align the piston rings on the piston. Upper oil control segment ring gap location Oil control spacer gap location Lower oil control segment ring gap location

SPECIAL TOOLS CHART Brush, Fuel Injector 310-205 Camshaft Alignment Tool 303-1565 Compressor, Piston Ring 303-D032 (D81L-6002-C) Crank Sensor Alignment Tool 303-1521 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Handle 205-153 (T80T-4000-W) Holding Tool, Flywheel 303-103 (T74P-8375-A) Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Installer, VCT Spark Plug Tube Seal 303-1247/2 Seal Installer, Fuel Injector 310-207 Sizer, Teflon® Seal 303-1567 Strap Wrench 303-D055 or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 2110

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Scheme 2112

MATERIAL SPECIFICATIONS

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Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

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1. Install the 4 engine piston oil coolers and the 4 bolts. Tighten to 10 Nm (89 lb-in).
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
4. Tighten the 10 original main bearing beam bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block main bearing bore diameter.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 29 Nm (21 lb-ft). Stage 3: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. Remove the 10 bolts in the sequence shown in illustration and the main bearing beam. Discard the main bearing beam bolts.
12. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
13. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine oil.
16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Install and tighten the 10 new main bearing beam bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Install the 4 upper bearings in the connecting rods and install the 4 lower bearings into the connecting rod caps. Lubricate the connecting rod bearings with clean engine oil.
20. Using the Piston Ring Compressor, install the 4 piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.
21. Install the 4 connecting rod caps and the 8 new bolts and tighten the bolts in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 29 Nm (21 lb-ft). Stage 3: Tighten an additional 90 degrees.
22. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC.
23. Install the adjustment shims in their original positions on the seat faces of the balance shaft assembly. With the balance shaft assembly marks in the TDC position, slowly install the balance shaft assembly onto the cylinder block to avoid interference between the crankshaft drive gear and the balance shaft assembly driven gear.
24. Install the 4 balance shaft assembly bolts and tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 42 Nm (31 lb-ft).
25. Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balance shaft assembly gear and the crankshaft gear.
26. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC. Remove the TDC Timing Peg.
27. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balance shaft assembly. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the «BALANCE SHAFT BACKLASH»(ref-494556-S05049956762012081400000) procedure. For additional information, refer to «BALANCE SHAFT BACKLASH»(ref-494556-S05049956762012081400000) in this service information.
28. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
29. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
30. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
31. Install the diamond washer.
32. Install the crankshaft sprocket.
33. Install the chain on the oil pump sprocket. Install the tensioner and the 2 shoulder bolts. Tighten to 10 Nm (89 lb-in). Push the tensioner spring down and position the spring under the shoulder bolt.
34. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft. Install the 6 bolts and tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Remove the Crankshaft Rear Main Oil Seal Installer.
35. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
36. Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the oil pan-to-engine block mating surface.
37. Position the oil pan onto the engine and install the 13 bolts finger-tight.
38. Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
39. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
40. Install the 2 cylinder head alignment dowels.
41. Install a new cylinder head gasket.
42. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 55 Nm (41 lb-ft). Stage 4: Tighten 90 degrees. Stage 5: Tighten an additional 90 degrees.
43. Install the 16 valve tappets in their original positions.
44. Apply 1 mm (0.039 in) beads of Gasket Maker to the exhaust rear camshaft bearing cap as shown in illustration.
45. Install the camshafts and bearing caps in their original location and orientation. Tighten the camshaft bearing caps 2 turns at a time in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
46. Install the front camshaft bearing cap and the 3 bolts. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
47. Install the 2 VCT solenoids and the 2 bolts. Tighten to 10 Nm (89 lb-in).
48. Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown in illustration. Tighten the retainer.
49. Install 2 new washers.
50. Install the intake and exhaust camshaft phaser and sprockets. Install the 2 bolts finger-tight.
51. Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket. Install the timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Install the timing chain arm. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
52. Using the edge of a vise, compress the timing chain tensioner plunger.
53. Using a small pick, push back and hold the ratchet mechanism.
54. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
55. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
56. Install the timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the paper clip to release the piston.
57. Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, tighten the exhaust camshaft phaser and sprocket bolt. Tighten to 72 Nm (53 lb-ft).
58. Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, tighten the intake camshaft phaser and sprocket bolt. Tighten to 72 Nm (53 lb-ft).
59. Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover. Apply a 2 mm (0.078 in) bead of Silicone Gasket and Sealant to the 5 center sealing surfaces of the front cover.
60. Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.
61. Install the engine front cover, the 20 bolts and 2 stud bolts. Tighten in the sequence shown in illustration as follows: Tighten 1 through 19 to 10 Nm (89 lb-in). Tighten 20 through 22 to 48 Nm (35 lb-ft).
62. Install the CKP sensor and the 2 bolts. Align the CKP sensor so the 2 bolts are located in the middle of the adjustment slots. Tighten to 7 Nm (62 lb-in).
63. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
64. Install a new diamond washer.
65. Position the crankshaft pulley onto the crankshaft and align the TDC marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) with the center line of the CKP sensor.
66. Install the Crankshaft Sensor Alignment Tool onto the TDC marked tooth on the crankshaft pulley. Install a new crankshaft pulley bolt and washer and tighten to 20 Nm (177 lb-in). Remove the Crankshaft Sensor Alignment Tool.
67. Use the Strap Wrench to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
68. Remove the Crankshaft TDC Timing Peg.
69. Remove the Camshaft Alignment Tool.
70. Turn the crankshaft clockwise one and three-fourths turns.
71. Install the Crankshaft TDC Timing Peg.
72. Rotate the crankshaft slowly clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. The TDC marked tooth on the crankshaft pulley will align with the center line of the CKP sensor.
73. Install the Camshaft Alignment Tool to check the position of the camshaft. If it is not possible to install the Camshaft Alignment Tool, the engine valve timing must be corrected.
74. Install the Crankshaft Sensor Alignment Tool. If the Crankshaft Sensor Alignment Tool does not align with the TDC marked tooth on the crankshaft pulley, loosen the 2 CKP sensor bolts and adjust the sensor until the tool is installed. Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in). Remove the Crankshaft Sensor Alignment Tool.
75. Remove the Camshaft Alignment Tool.
76. Remove the Crankshaft TDC Timing Peg.
77. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
78. Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter. Tighten to 63 Nm (46 lb-ft).
79. Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown in illustration.
80. Install the rear intake camshaft cap and the 2 bolts. Tighten the bolts in 2 stages: Stage 1: Tighten the bolts to 7 Nm (62 lb-in). Stage 2: Tighten the bolts to 16 Nm (142 lb-in).
81. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid seals.
82. Apply a 5.5 mm (0.216 in) drop of silicone gasket and sealant to the 6 locations shown in illustration.
83. Using a new gasket install the valve cover. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
84. Install the oil level indicator. Install the 4 coil-on-plugs and the 4 bolts. Tighten to 8 Nm (71 lb-in). Install the CAC intermediate tube mounting bracket, nut and bolt. Tighten to 8 Nm (71 lb-in).
85. Slide the vacuum hose assembly onto the valve cover tab and attach the 2 retainers.
86. Position the wiring harness onto the engine and attach the 7 retainers. Connect the 9 wiring harness electrical connectors.
87. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
88. Inspect the fuel injection pump housing gasket and replace as necessary.
89. Install the fuel injection pump housing, the 4 bolts and tighten in 2 stages. Stage 1: Tighten to 15 Nm (177 lb-in). Tighten an additional 60 degrees.
90. Slide the fuel injection pump tappet into the fuel injection pump housing.
91. Install a new fuel injection O-ring seal. Lubricate the O-ring seal with clean engine oil.
92. Install the fuel injection pump and loosely install 2 fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages. Stage 1: Tighten each bolt to 5 Nm (44 lb-in). Stage 2: Tighten each bolt an additional 55 degrees.
93. Install the fuel injection pump bracket and the 2 bolts. Tighten to 17 Nm (150 lb-in).
94. Inspect and, if necessary, install a new brake vacuum pump gasket.
95. Install the brake vacuum pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
96. Inspect and, if necessary, install a new thermostat housing gasket.
97. Install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
98. Install new lower Teflon® fuel injector seals. Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed. Install the new lower Teflon® seal on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tip. Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors.
99. Slide the Teflon® Seal Sizer down over the Teflon® seal.
100. Assemble the fuel injectors. Install the upper fuel injector O-ring seal support ring Install a new upper fuel injector O-ring seal. Lubricate the O-ring seal with clean engine oil. Install a new fuel injector retainer clip
101. Install the fuel injectors into the fuel rail.
102. Position the fuel rail and fuel injectors into the cylinder head and push down on the fuel rail face above the injectors. Install 5 new bolts and tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 26 degrees.
103. Install a new high pressure fuel tube and hand tighten the 2 flare nuts.
104. Loosely install the 2 high pressure fuel tube bracket bolts.
105. Tighten the 2 high pressure fuel tube flare nuts in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten an additional 30 degrees.
106. Tighten the 2 high pressure fuel tube bracket bolts to 10 Nm (89 lb-in).
107. Install the fuel injection pump insulator. Connect the fuel injection pump electrical connector.
108. Install the fuel rail insulator and the 2 pin-type retainers.
109. Install the fuel charge wiring harness and connect the 4 fuel injector electrical connectors.
110. Inspect and, if necessary, install a crankcase vent oil separator gasket.
111. Install the coolant bypass hose and the 2 clamps. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
112. Install the 2 KS and the 2 bolts. Tighten to 20 Nm (177 lb-in). Connect the 2 KS electrical connectors.
113. Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
114. Position the intake manifold and attach the 2 KS wiring harness retainers to the intake manifold. Connect the TB electrical connector and attach the wiring harness retainer to the TB. Connect the PCV hose.
115. Install the intake manifold and the 5 bolts. Tighten in the sequence shown in illustration to 18 Nm (159 lb-in).
116. Connect the 2 vacuum hoses to the intake manifold. Attach the vacuum tube retainer to the intake manifold.
117. Connect the MAP sensor, the FRP sensor and fuel charge harness electrical connectors.
118. Connect the 2 brake vacuum tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Insert the brake vacuum tube into the intake manifold quick connect fitting.
119. Install the EVAP canister purge valve and tube assembly. Connect the EVAP canister purge valve electrical connector.
120. Connect the EVAP tube quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Attach the 2 EVAP tube retainers.
121. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft). Connect the EOP switch electrical connector.
122. Install the CAC outlet tube and clamp. Tighten to 5 Nm (44 lb-in). Connect the EVAP tube quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Install the heater hose and clamp. Attach the heater hose retainer to the intake manifold.
123. Using a new O-ring seal, install the coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in). Install the idler pulley and bracket assembly, the bolt and the nut. Tighten to 25 Nm (18 lb-ft).
124. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (177 lb-in). Install the power steering pump bracket and the 4 bolts. Tighten to 25 Nm (18 lb-in). Install the generator and the 3 bolts. Tighten to 25 Nm (18 lb-in).
125. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-in).
126. Install the accessory drive belt, the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-in).
127. Install the RH halfshaft bracket and the 2 bolts. Tighten to 25 Nm (18 lb-in).
128. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers. Install the ground strap and nut. Tighten to 9 Nm (80 lb-in).
129. Connect the CHT sensor electrical connector and slide the insulator down. Attach the wiring harness retainer. Connect the ECT sensor electrical connector. Install the ground wire and bolt. Tighten to 20 Nm (177 lb-in).
130. Install 4 new turbocharger-to-cylinder head studs. Tighten to 17 Nm (150 lb-in). Install a new turbocharger gasket.
131. Install the turbocharger and 4 new nuts. Tighten in the sequence shown in illustration to 50 Nm (37 lb-ft).
132. Install the turbocharger heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
133. Using 2 new gaskets, install a new turbocharger oil return tube and the 4 bolts. Tighten to 10 Nm (89 lb-in).
134. Install a new turbocharger oil filter.
135. Using 4 new gaskets, install a new turbocharger oil supply tube and the 2 banjo bolts. Tighten to 25 Nm (18 lb-ft).
136. Connect the 2 turbocharger control vacuum hoses and clamps.
137. Connect the 2 turbocharger control vacuum hoses and 2 electrical connectors.
138. Using 2 new gaskets, install the turbocharger coolant tube and the 2 banjo bolts. Tighten to 28 Nm (21 lb-ft). Connect the turbocharger coolant tube and the 2 clamps.
139. Install the turbocharger inlet tube, bolt and the stud bolt. Tighten to 5 Nm (44 lb-in).
140. Position the EVAP canister purge valve and install the engine appearance cover mounting stud. Tighten to 5 Nm (44 lb-in).
141. Tighten the turbocharger inlet tube clamp to 5 Nm (44 lb-in).
142. Install the turbocharger outlet tube and the 2 bolts. Tighten to 5 Nm (44 lb-in).
143. Tighten the turbocharger outlet tube clamp to 5 Nm (44 lb-in).
144. Remove the engine from the Engine Stand.
145. Install the flexplate, the 6 new bolts and the Flywheel Holding Tool. Tighten in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).

SPECIAL TOOLS CHART 2, 200# Floor Crane, Fold Away 300-OTC1819E Adjustable Grip Arm, 1735A 014-00001 Protector, Differential Oil Seal (pair) 205-461 Powertrain Lift 014-00765 or equivalent Retainer, Torque Converter 307-566 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

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MATERIAL SPECIFICATIONS

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1. Lubricate the torque converter pilot hub with Multi-Purpose Grease. Remove the Torque Converter Retainer and bolt.
2. Using the Floor Crane and Spreader Bar, assemble the engine and transaxle.
3. Install the 3 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
4. Install the 3 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
5. Install the 3 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
6. Using the Floor Crane and Spreader Bar, position the engine and transaxle on the Powertrain Lift.
7. Install the Powertrain Lift and Adjustable Grip Arms.
8. Connect the Positive Crankcase Ventilation (PCV) tube to the turbocharger inlet pipe.
9. Connect the heater hose.
10. Install the wire terminal and nut on the generator. Tighten to 17 Nm (150 lb-in) and install the cap. Connect the wire harness electrical connector. Attach the 2 wiring harness retainers to the engine.
11. Install the 4 torque converter nuts. Tighten to 40 Nm (30 lb-ft).
12. Install the starter insulator.
13. Install the starter and the 2 stud bolts. Tighten to 35 Nm (26 lb-ft).
14. Install the 2 starter wire terminals, the ground wire and the 3 nuts. Tighten the ground wire nut to 18 Nm (159 lb-in). Tighten the large starter wire terminal nut to 12 Nm (106 lb-in). Tighten the small starter wire terminal nut to 5 Nm (44 lb-in). Install the starter cable cover.
15. Raise the engine and transaxle assembly into the vehicle. Install the engine mount, the 4 nuts and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
16. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten the 3 nuts to 63 Nm (46 lb-ft). Tighten the bolt to 80 Nm (59 lb-ft).
17. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
18. Connect the return hose and clamp to the power steering pump.
19. Install the A/C compressor, the 2 bolts and the nut. Tighten to 25 Nm (18 lb-ft).
20. Connect the 2 A/C compressor electrical connectors. Attach the wiring harness retainer to the A/C tube stud bolt.
21. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt on the A/C compressor.
22. Install a new circlip.
23. Install Differential Oil Seal Protector on the LH halfshaft seal.
24. Push the LH halfshaft into the transaxle so the circlip locks into the differential side gear. Pull the halfshaft inner end to make sure the circlip is locked.
25. Install the RH halfshaft in the transaxle and engage the halfshaft splines with the transaxle side gears and install the 2 halfshaft nuts. Tighten to 25 Nm (18 lb-ft).
26. Attach the 2 wiring harness retainers to the RH halfshaft support stud bolts.
27. Install a new engine oil filter. Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.
28. Connect the lower radiator hose and clamp.
29. Install the 2 transaxle-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
30. Connect the transaxle cooling tubes.
31. Install the 2 secondary latches onto the transaxle fluid cooler tubes.
32. Install the front subframe. For additional information, refer to «UNI-BODY, SUBFRAME AND MOUNTING SYSTEM»(ref-494619) .
33. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
34. Connect the fuel tube to the high pressure fuel pump.
35. Connect the vacuum check valve to the power brake booster.
36. Connect the Evaporative Emission (EVAP) tube to the EVAP purge valve. For additional information, refer to the Quick Connect Coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
37. Install the ground wire and nut to the RH inner fender. Tighten to 11 Nm (97 lb-in).
38. Attach the wiring harness retainer to the valve cover stud bolt.
39. Connect the 2 engine wiring harness electrical connectors. Attach the wiring harness retainer to the cowl.
40. Install the Charge Air Cooler (CAC) inlet tube and the 2 clamps.
41. Connect the CAC outlet tube and the clamp.
42. Connect the transaxle selector lever cable end to the manual control lever and install the 2 bracket bolts. Tighten to 25 Nm (18 lb-ft).
43. Connect the upper radiator hose and the heater hose. Connect the heater hose quick connect coupling. Attach the hoses to the 2 retaining clips.
44. Connect the wiring harness electrical connector.
45. Attach the wiring harness retainer to the transaxle mount bracket stud bolt.
46. Install the ground wire and the nut. Tighten to 9 Nm (80 lb-in). Connect the battery current sensor electrical connector.
47. Connect the power feed to the battery terminal and install the 2 nuts. Tighten to 9 Nm (80 lb-in). Connect the generator current sensor electrical connector.
48. Install the Transmission Control Module (TCM) bracket and the nut. Tighten to 9 Nm (80 lb-in). Connect the TCM electrical connector and attach the 3 wiring harness retainers.
49. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
50. Install the engine Air Cleaner (ACL) and ACL outlet pipe assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
51. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
52. Fill the engine with clean engine oil.
53. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
54. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.