Engine - 2.0L Zetec: Removal & Installation Ford Escape I

Removal

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

1. Release the fuel system pressure. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142374) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
3. Remove the air cleaner outlet pipe..
4. Using the special tool, disconnect the fuel tube.
5. Disconnect the accelerator cable and, if equipped, the speed control actuator cable.
6. Disconnect the fuel pulse damper vacuum hose.
7. Disconnect the fuel injector electrical connectors. Remove the harness from the valve cover stud bolt.
8. Disconnect the throttle position (TP) sensor electrical connector.
9. Disconnect the idle air control (IAC) electrical connector and unclip the harness from the bracket.
10. Remove the main engine control sensor wiring connector from the mounting bracket.
11. Disconnect the powertrain control module (PCM) wire harness from the bracket.
12. Disconnect the heated oxygen sensor (HO2S) wiring harness from the bracket.
13. Remove the HO2S wiring harness retainer.
14. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
15. Detach the CHT sensor wiring harness from the clip, and remove the clip.
16. Disconnect the brake booster vacuum supply hose.
17. Disconnect the four vacuum hoses.
18. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
19. Remove the exhaust gas recirculation (EGR) valve bolts.
20. Remove the intake manifold. Remove the two nuts and five bolts in the sequence shown.
21. Remove the right side intake manifold stud.
22. Remove the intake manifold and the gaskets. Inspect the gaskets and discard if damaged.

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

1. Position the intake manifold and gaskets.
2. Install the right side intake manifold stud.
3. Tighten the nuts and bolts using the sequence shown.
4. Install the EGR valve bolts.
5. Connect the PCV vacuum hose.
6. Connect the four vacuum hoses.
7. Connect the brake booster vacuum supply hose to the intake manifold.
8. Install the (CHT) sensor wire clip, and attach the CHT wiring harness.
9. Connect the (CHT) sensor.
10. Install the retainer for the HO2S wiring harness mount.
11. Connect the HO2S sensor wiring harness to the bracket.
12. Connect the PCM wiring harness to the bracket.
13. Connect the main engine control sensor wiring connector to the mounting bracket.
14. Connect the IAC electrical connector and attach the wiring harness to the bracket.
15. Connect the TP sensor electrical connector.
16. Connect the fuel injector electrical connectors. Position the harness back onto the valve cover stud.
17. Connect the fuel pulse damper vacuum hose.
18. Connect the accelerator cable and, if equipped, the speed control actuator cable.
19. Connect the fuel tube. Install the safety clip.
20. Install the air cleaner outlet pipe. .
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

1. Remove the air cleaner outlet pipe.
2. Remove the ignition wires from the spark plugs.
3. Disconnect the throttle cables. Disconnect the speed control actuator cable (if equipped). Disconnect the accelerator cable.
4. Disconnect the catalyst monitor and heated oxygen sensor electrical connectors. Detach the electrical connectors from the bracket.
5. Remove the wiring harness anchors from the valve cover studs and position the wiring harness aside.
6. Remove the valve cover. Remove the studbolts Remove the bolts.
7. Clean and inspect the sealing surfaces of the valve cover and the cylinder head. Both surfaces must be clean and flat.
8. To install, reverse the removal procedure. Install a new valve cover gasket if damaged.

Scheme 567

Scheme 568

Scheme 569

Scheme 570

1. Raise and support the vehicle.
2. Remove the RF wheel and tire assembly.
3. Remove the bolts and the RH lower splash shield.
4. Loosen the bolt retaining the crankshaft pulley.
5. Remove the accessory drive belt.
6. Remove the bolt and the crankshaft pulley.
7. To install, reverse the removal procedure.

Scheme 571

Scheme 572

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .
2. Remove the crankshaft sprocket and timing belt guide.
3. Using the special tool, remove the crankshaft front seal from the oil pump.

Scheme 573

Scheme 574

1. Using the special tool, install a new crankshaft front seal.
2. Install the timing belt guide and crankshaft sprocket.
3. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204616-S25186496132005111200000) .
3. Remove the bolts and the lower timing belt cover.
4. Lower the vehicle.
5. Install the special tool.
6. Remove the ground strap.
7. Remove the engine mount upper bracket.
8. Remove the studs.
9. Remove the knock sensor connector.
10. Remove the bolts and the upper timing belt cover.
11. To install, reverse the removal procedure.

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Scheme 592

Scheme 593

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
3. Remove the air cleaner outlet pipe.
4. Remove the spark plugs.
5. Disconnect the throttle cables. If equipped, disconnect the speed control actuator cable. Disconnect the accelerator cable.
6. Disconnect the catalyst monitor and heated oxygen sensor electrical connectors. Detach the electrical connectors from the bracket.
7. Remove the wiring harness anchors from the valve cover studs and position the wiring harness aside.
8. Remove the valve cover. Remove the studbolts. Remove the bolts.
9. Clean and inspect the sealing surfaces of the valve cover and cylinder head. Both surfaces must be clean and flat.
10. Remove the catalytic converter.
11. Remove the bolt and nut and position the coolant tube aside.
12. Remove the wheel and tire assembly.
13. Remove the RH lower splash shield.
14. Rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder).
15. Remove the stud.
16. Install the special tool.
17. Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder).
18. Loosen the coolant pump pulley bolts.
19. Loosen the crankshaft pulley bolt.
20. Rotate the tensioner and remove the accessory drive belt.
21. Remove the bolt and the crankshaft pulley.
22. Remove the bolts and the lower timing belt cover.
23. Install the special tool.
24. Detach the ground strap.
25. Remove the nuts, the bolt and the engine mount upper bracket.
26. Remove the studs.
27. Detach the knock sensor electrical connector from the upper timing cover.
28. Remove the bolts and the upper timing cover.
29. Remove the coolant pump pulley.
30. Remove the accessory drive belt idler pulley.
31. Remove the bolts and the engine mount lower bracket.
32. Relieve the tension on the timing belt tensioner pulley. Loosen the tensioner pulley bolt. Release the tension on the timing belt by disconnecting the tensioner tab from the timing cover back plate.
33. Remove and discard the timing belt. Slide the timing belt off the camshaft sprockets and the crankshaft sprocket.

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

Scheme 624

Scheme 625

Scheme 626

Scheme 627

Scheme 628

Scheme 629

1. Loosen the camshaft pulleys. Remove the blanking plug from the exhaust camshaft pulley. Loosen the exhaust camshaft pulley bolt. Loosen the intake camshaft pulley bolt.
2. Install the camshaft alignment timing tool on the back of the camshafts.
3. Confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg.
4. Position a new timing belt in place. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
5. Pre-tension the timing belt. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key.
6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
7. While holding the adjusting washer in position, tighten the bolt.
8. Tighten the bolt on the intake camshaft sprocket.
9. Tighten the bolt on the exhaust camshaft sprocket in three stages. Stage 1: Tighten the bolt to 50 Nm (36 lb-ft). Stage 2: Remove the TDC peg and the camshaft alignment timing tool. Stage 3: Tighten the bolt to 115-125 Nm (85-92 lb-ft).
10. Screw in the new oil plug on the variable camshaft timing assembly.
11. Check the valve timing by inserting the special tools and correct the alignment as necessary. Screw in special tool 303-574 and make sure that the crankshaft is resting against the special tool. Insert special tool 303-465 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment. Remove the special tools.
12. Install the front engine mount lower bracket.
13. Install the accessory drive belt idler pulley.
14. Install the coolant pump pulley. Hand-tighten the bolts.
15. Position the upper timing belt cover and install the bolts.
16. Install the studs.
17. Connect the knock sensor electrical connector to the upper timing belt cover.
18. Install the engine mount upper bracket, the nuts and the bolt.
19. Attach the ground strap and install the nut.
20. Position the lower timing belt cover and install the bolts.
21. Position the crankshaft pulley and install the bolt. Hand-tighten the bolt.
22. Rotate the tensioner and install the accessory drive belt.
23. Tighten the crankshaft pulley bolt.
24. Tighten the coolant pump pulley bolts.
25. Position the RH lower splash shield and install the bolts.
26. Install the wheel and tire assembly.
27. Install the stud.
28. Install the coolant tube.
29. Install the catalytic converter.
30. Inspect the valve cover gasket. Install a new gasket, if necessary.
31. Position the valve cover. Install the studbolts. Install the bolts.
32. Connect the wiring harness anchors to the valve cover studs.
33. Attach the catalyst monitor and heated oxygen sensor electrical connectors to the bracket. Connect the electrical connectors.
34. Connect the throttle cables. Connect the accelerator cable. If equipped, connect the speed control actuator cable.
35. Install the spark plugs.
36. Install the air cleaner outlet pipe.
37. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .

Scheme 630

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .
2. Lower the vehicle.
3. Remove the special tool.
4. Remove the bolts and the camshaft timing sprockets.

Scheme 631

Scheme 632

1. Install the camshaft sprockets onto the camshafts and loosely install the bolts.
2. Install the special tool.
3. Raise the vehicle.
4. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .

Scheme 633

Scheme 634

1. Remove the spark plugs.
2. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204616-S16271311512005111200000) .
3. Install the air line with an adapter in the spark plug hole and turn on the air supply.
4. Install the special tools, compress the valve spring, and remove the valve spring retainer and valve spring.
5. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) . Install new parts as necessary.
6. Use the special tools to remove the valve stem seal.

Scheme 635

Scheme 636

1. Remove the air pressure from the spark plug adapter and inspect the valve for damage. Rotate the valve and check the valve for eccentric movement during rotation. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
2. If the condition of the valve is satisfactory, apply Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H to the valve stem and hold the valve closed. Apply the air pressure within the cylinder.
3. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSSM2C153- H and using the special tool install the valve stem seals onto the cylinder head valve guides.
4. Place the valve spring in position over the valve and install the valve spring retainer.
5. Using the special tools compress the valve spring and install the valve spring retainer keys. Remove the special tools.
6. Remove the air pressure.
7. Remove the air line adapter.
8. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204616-S16271311512005111200000) .
9. Install the spark plugs.

Scheme 637

Scheme 638

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .
2. Remove the camshaft alignment tool.
3. Use a feeler gauge to measure each valve's clearance and record its location.
4. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-204616-S22542858562005111200000) .
5. Remove the valve tappets from the cylinder head.
6. Select tappets and mark installation location.

Scheme 639

Scheme 640

1. Install the valve tappets.
2. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-204616-S22542858562005111200000) .
3. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet.
4. Install the camshaft alignment tool.
5. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .

1. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-204616-S22542858562005111200000) .
2. Remove the valve tappets from the cylinder head.
3. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
4. To install, reverse the removal procedure. Lubricate the valve tappet with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.

Scheme 641

1. Remove the camshaft timing sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS - TIMING SPROCKETS»(ref-204616-S01606466582005111200000) .
2. Use a feeler gauge to measure each valve's clearance and record its location.
3. Remove the camshafts. Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown. Remove the bolts. Remove the caps.
4. Inspect the camshaft runout, lobe-lift and journal diameter for wear. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) . Discard the oil seals.
5. Remove the valve tappets from the cylinder head.
6. Select tappets and mark installation location.

Scheme 642

Scheme 643

1. Install the valve tappets.
2. Install the camshafts. Position the camshafts and camshaft journal caps. Install the bolts and tighten the bolts in several two-turn passes using the sequence shown.
3. Coat the sealing surface of the front camshaft journal cap with Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5.
4. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet.
5. Install the camshaft alignment timing tool.
6. Using the special tool, install new camshaft front oil seals.
7. Install the camshaft timing sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS - TIMING SPROCKETS»(ref-204616-S01606466582005111200000) .

Scheme 644

1. Remove the camshaft timing sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS - TIMING SPROCKETS»(ref-204616-S01606466582005111200000) .
2. Using the special tool, remove the camshaft oil seals.

Installation

1. Using the special tool, install new camshaft front oil seals.
2. Install the camshaft timing sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS - TIMING SPROCKETS»(ref-204616-S01606466582005111200000) .

Scheme 645

1. Remove the catalytic converter.
2. Lower the vehicle.
3. Remove the oil level indicator and tube bracket bolt.
4. Remove the six bolts and three nuts and remove the exhaust manifold. Discard the gasket.

Scheme 646

Scheme 647

1. Carefully clean both sealing surfaces. Position a new gasket.
2. Install the exhaust manifold and tighten using the sequence shown.
3. Install the oil level indicator and tube.
4. Install the catalytic converter.

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204619) .
2. Relieve the fuel system pressure. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142374) .
3. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204616-S16271311512005111200000) .
4. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139334) .
5. Disconnect the vacuum hose.
6. Disconnect the vacuum hose.
7. Disconnect the knock sensor (KS) electrical connector.
8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
9. Detach the fuel charging wiring harness.
10. Remove the bolt from the accelerator cable support bracket.
11. Remove the bolt from the generator mounting bracket.
12. Disconnect the wiring harness retainer from the intake manifold.
13. Disconnect the ignition coil and the radio interference suppressor electrical connectors.
14. Remove the bolt from the power steering pressure hose support bracket.
15. Position the thermostat housing aside. Disconnect the electrical harness retainer. Remove the bolts.
16. Remove the bolt and the oil level indicator tube.
17. Using the special tool, disconnect the fuel lines.
18. Remove the power steering bracket retainers and position aside.
19. Raise the vehicle.
20. Install the engine mount lower bracket.
21. Lower the vehicle.
22. Install the studs.
23. Install the engine mount upper bracket.
24. Remove the special tool.
25. Remove the cylinder head bolts in the sequence shown and remove the cylinder head. Discard the gasket. Discard the bolts.

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
2. Install a new head gasket on the cylinder block.
3. Install the cylinder head and tighten the bolts in three stages using the sequence shown. Stage 1: Tighten the bolts to 20 Nm (15 lb-ft). Stage 2: Tighten the bolts to 40 Nm (30 lb-ft). Stage 3: Tighten the bolts an additional 90 degrees.
4. Install the special tool.
5. Remove the engine mount upper bracket.
6. Remove the studs.
7. Raise and support the vehicle.
8. Remove the engine mount lower bracket.
9. Drain the engine oil and install a new oil filter. Fill the crankcase with Super Premium 5W-20 SAE Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.
10. Lower the vehicle.
11. Position the power steering bracket back.
12. Install the oil level indicator tube and the bolt.
13. Install the thermostat housing and the bolts.
14. Install the bolt for the power steering pressure hose support bracket.
15. Connect the ignition coil and the radio interference suppressor electrical connectors.
16. Connect the wiring harness retainer to the intake manifold.
17. Install the bolt in the generator mounting bracket.
18. Connect the fuel charging wiring harness retainer.
19. Connect the knock sensor (KS) electrical connector.
20. Connect the cylinder head temperature (CHT) sensor electrical connector.
21. Connect the vacuum hose.
22. Connect the vacuum hose.
23. Install the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139334) .
24. Connect the fuel line and safety clip.
25. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204616-S16271311512005111200000) .
26. Install the accelerator control cable support bracket bolt.
27. Drain the engine oil and fill the engine with clean engine oil.
28. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204619) .

Scheme 683

Scheme 684

1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204619) .
2. Remove the oil filter.
3. Remove the oil cooler. Disconnect the coolant hoses. Remove the cooler mounting bolt.
4. Carefully clean the sealing surfaces. Install a new oil filter.
5. To install, reverse the removal procedure.

Scheme 685

1. Raise and support the vehicle.
2. Disconnect the oil pressure sender electrical connector.
3. Remove the oil pressure sender.
4. To install, reverse the removal procedure.

Scheme 686

1. Remove the bolt and the oil level indicator and tube.
2. To install, reverse the removal procedure. Install a new O-ring seal if damaged.

Scheme 687

Scheme 688

1. Remove the catalytic converter.
2. Drain the engine oil. Install the drain plug.
3. Remove the 17 bolts and the oil pan.

1. Clean and inspect the mounting faces of both the oil pan and the cylinder block with Metal Surface Cleaner F4AZ- 19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Both surfaces must be flat, clean and dry.
2. Install the oil pan. Tighten the bolts using the sequence shown in two stages: Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten 12 Nm (9 lb-in).
3. Install the catalytic converter.
4. Fill the crankcase with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204616-S03893901832005111200000) .
3. Remove the crankshaft sprocket and the timing belt guide.
4. Remove the coolant tube bracket bolt.
5. Remove the bolts and position the A/C compressor aside.
6. Remove the lower A/C bracket bolts.
7. Remove the six lower crankcase-to-transmission bolts.
8. Remove the lower crankcase-to-upper crankcase bolts and the lower crankcase.
9. Remove the bolts and the accessory drive belt tensioner.
10. Remove the bolts and the oil pump.

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

1. Clean and inspect the mounting faces of both the oil pump and the cylinder block. Both surfaces must be flat and clean.
2. Install a new oil pump gasket, the oil pump and the bolts. Tighten the bolts in two stages: Stage 1: Tighten the bolts to 6 Nm (53 lb-in). Stage 2: Tighten an additional 45 degrees.
3. Install a new crankcase front seal.
4. Apply a 3 mm (0.1 inch) bead of silicone gasket and sealant in four places where the oil seal retainers meet the cylinder block.
5. Install a new gasket, the lower crankcase and the bolts.
6. Install the lower crankcase-to-transmission bolts.
7. Install the lower A/C bracket bolts.
8. Position the A/C compressor and install the bolts.
9. Install the coolant tube bracket bolt.
10. Install the accessory drive belt tensioner and the bolts.
11. Install the crankshaft sprocket and the timing guide.
12. Install the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204616-S03893901832005111200000) .
13. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-204616-S21773006842005111200000) .

Scheme 703

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-204616-S34825866362005111200000) .
2. Remove the oil pump screen cover and tube. Remove and discard the gasket.
3. Carefully clean both sealing surfaces.
4. To install, reverse the removal procedure. Install a new gasket.

Scheme 704

1. Remove the clutch.
2. Remove the bolts and the flywheel.
3. To install, reverse the removal procedure.

Scheme 705

1. Remove the flywheel. For additional information, refer to «FLYWHEEL»(ref-204616-S05716600302005111200000) .
2. Using the special tool, remove the crankshaft rear oil seal.
3. Inspect the crankshaft rear oil seal area.

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flywheel. For additional information, refer to «FLYWHEEL»(ref-204616-S05716600302005111200000) .

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

1. Install the special tool.
2. Disconnect the ground strap.
3. Remove the engine mount upper bracket.
4. Disconnect the ground wire.
5. Disconnect the power steering line bracket.
6. Disconnect the power steering line bracket and position the line aside.
7. Remove the engine mount.
8. To install, reverse the removal procedure.

Scheme 714

On All vehicles

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

1. Place the transmission in neutral.
2. Disconnect the fuel hose spring lock couplings. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142374) .
3. Remove the hood. Disconnect the washer hose. Remove the four bolts and the hood.
4. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
5. Remove the air cleaner housing bolt. Disconnect the mass air flow sensor electrical connector. Remove the air cleaner housing bolt.
6. Remove the engine air cleaner (ACL) and outlet tube. Disconnect the accelerator cable. Disconnect the emission tube and hose. Disconnect the crankcase ventilation hose. Loosen the clamp. Remove the ACL and outlet pipe as an assembly.
7. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204619) .
8. Recover the A/C system refrigerant. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139311) .
9. Disconnect the throttle cables and, if equipped, the speed control cable.
10. Remove the throttle cable bracket.
11. Disconnect the exhaust gas recirculation (EGR) vacuum regulator valve. Disconnect the electrical connector. Disconnect the vacuum hoses.
12. Disconnect the brake booster vacuum supply hose.
13. Disconnect the powertrain control module (PCM) wire harness and ground.
14. Disconnect the ground wire.
15. Disconnect the wire harness connector and the harness retainer clips.
16. Disconnect the power distribution box electrical connectors.
17. Disconnect the vacuum lines at the evaporative emission (EVAP) canister.
18. Disconnect the upper radiator hose.
19. Remove the power steering hose bracket bolt.
20. Remove the power steering hose bracket bolt.
21. Remove the upper power steering pump bolts.
22. Disconnect the heater hoses.
23. Remove the speed control unit (if equipped) and position aside.
24. Remove the catalytic converter. .
25. Remove the nuts and the bracket.
26. Remove the wheel center caps, if equipped.
27. Remove the LH and RH wheel and tire assembly. Remove the wheel nuts. Remove the wheel and tire assembly.
28. Remove the bolts and the right front lower splash shield.
29. Disconnect the coolant hose.
30. Disconnect the coolant hose.
31. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
32. Disconnect the A/C clutch field coil electrical connector.
33. Remove the A/C manifold and tube assembly bolt and disconnect the A/C manifold and tube assembly.
34. Remove the bolts and the A/C compressor.
35. Drain the transaxle fluid. Install the drain plug when finished.
36. Remove and discard both front axle wheel hub nuts.
37. Separate the lower control arms from the front wheel knuckles. Remove the pinch bolts and nuts. Separate the lower control arms from the front wheel knuckles.
38. Using the special tool, separate the halfshafts from the front wheel knuckles.
39. Using the special tools, remove the halfshafts. 4x2 vehicles
40. Disconnect the shifter linkages. All vehicles
41. Disconnect the block heater electrical connector.
42. Remove the front transaxle mount through bolt.
43. Drain the engine oil.
44. Remove the engine oil filter. 4x4 vehicles
45. Remove the transfer case. For additional information, refer to «TRANSFER CASE»(ref-194831) . All vehicles
46. Remove the intermediate shaft bracket and the intermediate shaft as an assembly.
47. Remove the engine to transaxle bolts.
48. Disconnect the lower radiator hose.
49. Disconnect the power steering pressure sensor.
50. Remove the lower power steering pump bolts and position the pump aside.
51. Lower the vehicle.
52. Disconnect the power steering hose brackets at the back and position the hoses aside. 4x4 vehicles
53. Remove the shifter cables. Remove the clips and remove the cable ends from the shifter levers. Remove the cables from the brackets and position aside. All vehicles
54. Remove the clutch slave cylinder bolts.
55. Remove the clutch slave cylinder line from the bracket and position the clutch slave cylinder aside.
56. Support the engine using a suitable lifting device.
57. Remove the rear transaxle mount.
58. Remove the front support insulator and bracket. Remove the five bolts. Remove the front support insulator and bracket.
59. Remove the LH transaxle mount.
60. Disconnect the ground cable.
61. Remove the RH engine mount upper bracket.
62. Install the special tool and a suitable lifting device and remove the engine and transaxle as an assembly.
63. Disconnect the generator electrical connectors.
64. Disconnect the electrical connectors. Disconnect the knock sensor electrical connector. Disconnect the oil pressure sender electrical connector. Disconnect the starter electrical connector.
65. Disconnect the vehicle speed sensor electrical connector.
66. Remove the bolt and disconnect the ground wire from the bell housing.
67. Disconnect the crankshaft position (CKP) sensor electrical connector.
68. Disconnect the fuel charging wiring harness electrical connector.
69. Disconnect the PCM wiring harness from the bracket.
70. Disconnect the ground wire.
71. Disconnect the reversing lamp switch electrical connector.
72. Disconnect the ignition coil electrical connector.
73. Remove the wiring harness. Disconnect the differential pressure feedback EGR system electrical connector. Remove the wiring harness from the brackets and remove the harness.
74. Remove the bolts and the starter.
75. Remove the starter wiring harness.
76. Remove the engine-to-transaxle bolts.
77. Remove the engine-to-transaxle bolts and remove the transaxle.

Scheme 775