Engine - 2.3L - (Except Hybrid): Removal & Installation Ford Escape I рестайлинг

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-232219) .
3. Disconnect the crankcase vent hose.
4. Remove the 2 coolant vent tube bracket nuts. Position the vent tube and brackets aside.
5. Disconnect the camshaft position (CMP) sensor electrical connector.
6. Disconnect the fuel rail pressure and temperature sensor electrical connector.
7. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
8. Disconnect the vacuum tube from the intake manifold. Detach the pin-type retainer and position the vacuum tube aside.
9. Remove the 2 accelerator cable bracket nuts. Position the accelerator cable and brackets aside.
10. Remove the power steering tube bracket nut. Position the power steering tube and bracket aside.
11. Detach all of the wiring harness retainers from the valve cover studs and position the harness aside.
12. Remove the 14 valve cover retainers, the valve cover and gasket.

Scheme 1

1. Clean and inspect the sealing surfaces.
2. Install the valve cover, gasket and retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs.
4. Position the power steering tube and bracket. Tighten to 6 Nm (53 lb-in).
5. Position the accelerator control cable and brackets. Tighten to 6 Nm (53 lb-in).
6. Attach the vacuum tube and the pin-type retainer to the intake manifold.
7. Connect the CHT sensor electrical connector.
8. Connect the fuel rail pressure and temperature sensor electrical connector.
9. Connect the CMP sensor electrical connector.
10. Install the coolant vent tube, brackets and nuts. Tighten to 6 Nm (53 lb-in).
11. Connect the crankcase vent hose.
12. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-232219) .

Scheme 2

Scheme 3

1. For additional information, refer to the appropriate PROCEDURES.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
3. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .
4. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
5. Install the special tool in the slots on the rear of both camshafts.
6. Remove the engine plug bolt.
7. Install the special tool.
8. Install the special tools.
9. Remove the crankshaft pulley. Remove the crankshaft pulley bolt and washer. Remove the crankshaft pulley.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Install the crankshaft pulley and hand-tighten the bolt.
2. Install a standard 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
3. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
4. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
5. Remove the special tool.
6. Remove the special tool.
7. Turn the engine 2 complete revolutions.
8. Turn the crankshaft until the No. 1 piston is at TDC.
9. Install the special tool.
10. Using the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
11. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
12. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
13. Install the engine plug bolt. To install, tighten to 20 Nm (15 lb-ft).
14. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
15. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .

1. Remove the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-232194-S30522316132006051600000) and «CRANKSHAFT PULLEY»(ref-232194-S29519945712006051600000) .
2. Using the special tool, remove the crankshaft front oil seal.

Installation

1. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-232194-S30522316132006051600000) and «CRANKSHAFT PULLEY»(ref-232194-S29519945712006051600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE-TRANSMISSION - CD4E»(ref-232215) .
3. Remove the 6 bolts and the flexplate.

Scheme 12

1. Install the flexplate and tighten the bolts in the sequence shown 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).
2. Install the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE-TRANSMISSION - CD4E»(ref-232215) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-232227) and «MANUAL TRANSAXLE-TRANSMISSION»(ref-232237) .
3. Remove the 6 bolts and the flywheel.

1. Install the flywheel and tighten the bolts in the sequence shown 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).
2. Install the clutch and manual transaxle. For additional information, refer to «CLUTCH»(ref-232227) and «MANUAL TRANSAXLE-TRANSMISSION»(ref-232237) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the flexplate or flywheel. For additional information, refer to «FLEXPLATE»(ref-232194-S40189356292006051600000) or «FLYWHEEL»(ref-232194-S01906727412006051600000) .
3. Remove the 17 bolts and the oil pan.
4. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear oil seal with retainer plate and bolts. To install, tighten in the sequence shown to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan and cylinder block mating surfaces.
4. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
5. Install the 4 bolts. To install, tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
7. Install the flexplate or flywheel. For additional information, refer to «FLEXPLATE»(ref-232194-S40189356292006051600000) or «FLYWHEEL»(ref-232194-S01906727412006051600000) .

Scheme 17

Scheme 18

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
3. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .
4. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-232194-S30167179762006051600000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the special tool in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the special tool.
9. Install the special tools.
10. Remove the crankshaft pulley. Remove the crankshaft pulley bolt and washer. Remove the crankshaft pulley.
11. Using the special tool, remove the crankshaft front oil seal.
12. Remove the 3 bolts and the coolant pump pulley.
13. Remove the 2 power steering pump bolts.
14. Remove the remaining bolts and position the power steering pump aside.
15. Disconnect the crankshaft position (CKP) sensor electrical connector.
16. Remove and discard the CKP sensor.
17. Remove the bolts and the engine front cover.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8 mm bolts to 10 Nm (89 lb-in). Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
4. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
5. Install the 2 remaining power steering pump bolts. Tighten to 25 Nm (18 lb-ft).
6. Install the coolant pump pulley and bolts. Tighten to 20 Nm (15 lb-ft).
7. Using the special tool, install the crankshaft front oil seal.
8. Install the crankshaft pulley and hand-tighten the bolt.
9. Install a standard 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
10. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
11. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
12. Remove the special tool.
13. Remove the special tool.
14. Turn the engine 2 complete revolutions.
15. Turn the crankshaft until the No. 1 piston is at TDC.
16. Install the special tool.
17. Using the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
18. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
19. Install the CKP sensor. Do not tighten the bolts at this time.
20. Adjust the CKP sensor alignment jig. Tighten the bolts to 7 Nm (62 lb-in).
21. Connect the CKP sensor electrical connector.
22. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
23. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
24. Install the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
25. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-232194-S30167179762006051600000) .
26. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
3. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .
4. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-232194-S30167179762006051600000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the special tool in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the special tool.
9. Install the special tools.
10. Remove the crankshaft pulley. Remove the crankshaft pulley bolt and washer. Remove the crankshaft pulley.
11. Using the special tool, remove the crankshaft front oil seal.
12. Remove the 3 bolts and the coolant pump pulley.
13. Remove the 2 power steering pump bolts.
14. Remove the remaining bolts and position the power steering pump aside.
15. Disconnect the crankshaft position (CKP) sensor electrical connector.
16. Remove and discard the CKP sensor.
17. Remove the bolts and the engine front cover.
18. Remove the timing chain tensioner. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner. Remove the bolts and timing chain tensioner.
19. Remove the RH timing chain guide.
20. Remove the timing chain.
21. Remove the bolts and the LH timing chain guide.
22. Remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

Scheme 28

Scheme 29

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and the bolts. To install, tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the RH timing chain guide.
5. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 65 Nm (48 lb-ft).
7. Clean and inspect the mounting surfaces of the engine and the front cover.
8. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the front cover.
9. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8 mm bolts to 10 Nm (89 lb-in). Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
10. Position the power steering pump and install the bolts. To install, tighten to 25 Nm (18 lb-ft).
11. Install the remaining 2 power steering pump bolts. To install, tighten to 25 Nm (18 lb-ft).
12. Install the coolant pump pulley and bolts. To install, tighten to 20 Nm (15 lb-ft).
13. Using the special tool, install the crankshaft front oil seal.
14. Install the crankshaft pulley and hand-tighten the bolt.
15. Install a standard 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
16. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
17. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
18. Remove the special tool.
19. Remove the special tool.
20. Turn the engine 2 complete revolutions.
21. Turn the crankshaft until the No. 1 piston is at TDC.
22. Install the special tool.
23. Using the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
24. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
25. Install the CKP sensor. Do not tighten the bolts at this time.
26. Adjust the CKP sensor alignment jig. Tighten the bolts to 7 Nm (62 lb-in).
27. Connect the CKP sensor electrical connector.
28. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
29. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
30. Install the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
31. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-232194-S30167179762006051600000) .
32. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .

Scheme 30

1. For additional information, refer to the «PROCEDURES»(ref-232194-S35015739332006051600000) .

Scheme 31

Scheme 32

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Check the valve clearance prior to removal of the camshafts. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-232194-S25267039512006051600000) .
3. Remove the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-232194-S09826461572006051600000) .
4. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
5. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts in the sequence shown, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.

Scheme 33

1. Install the camshafts, bearing caps and special tool. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
2. Install the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-232194-S09826461572006051600000) .

Scheme 34

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «CAMSHAFTS»(ref-232194-S42676845502006051600000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) .
4. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply.
5. Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply and install the spark plug.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Tighten the spark plugs to 15 Nm (11 lb-ft).
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «CAMSHAFTS»(ref-232194-S42676845502006051600000) .

Scheme 35

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «CAMSHAFTS»(ref-232194-S42676845502006051600000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) .
4. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply.
5. Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
6. Using the special tools, remove and discard the valve seal.

Scheme 36

Scheme 37

1. Install the valve stem seal installation sleeve.
2. Using the special tool, install the valve seal.
3. Using the special tools, install the valve spring. Insert 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. Disconnect the compressed air supply and install the spark plug.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Tighten the spark plugs to 15 Nm (11 lb-ft).
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «CAMSHAFTS»(ref-232194-S42676845502006051600000) .

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the camshafts. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «CAMSHAFTS»(ref-232194-S42676845502006051600000) .
3. Remove and inspect the valve tappets. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) .
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-232262) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .
4. Remove the valve tappets. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «VALVE TAPPETS»(ref-232194-S07656012862006051600000) .
5. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-232194-S26804502752006051600000) .
6. Remove the exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
7. Disconnect the radio ignition interference capacitor electrical connector.
8. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
9. Disconnect the EGR coolant hose from the EGR valve.
10. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
11. Remove the bolts and the cylinder head. Discard the bolts.

Scheme 38

Scheme 39

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) .
3. Apply silicone gasket and sealant to the locations shown.
4. Install a new head gasket.
5. Install new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
6. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
7. Connect the EGR coolant hose to the EGR valve.
8. Connect the exhaust gas recirculation (EGR) valve electrical connector.
9. Connect the radio ignition interference capacitor electrical connector.
10. Install the exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
11. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-232194-S26804502752006051600000) .
12. Install the valve tappets. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «VALVE TAPPETS»(ref-232194-S07656012862006051600000) .
13. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .

Scheme 40

Scheme 41

1. For additional information, refer to the appropriate PROCEDURES.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .
4. Disconnect the 2 coolant hoses from the oil cooler.
5. Disconnect the oil pressure sender electrical connector.
6. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
7. To install, reverse the removal procedure.
8. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the oil pressure sender electrical connector.
4. Remove the oil pressure sender. To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure. Apply pipe sealant with Teflon® to the oil pressure sender threads.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Drain the engine oil, then install the drain plug. Tighten to 28 Nm (21 lb-ft).
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-232194-S37696991442006051600000) .
4. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-232194-S17480435632006051600000) .
5. Remove the 4 oil pan-to-bellhousing bolts.
6. Remove the 13 bolts and the oil pan.

Scheme 42

Scheme 43

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the oil pan. Position the oil pan and install the 2 rear oil pan bolts finger-tight.
3. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
4. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
5. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
6. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-232194-S17480435632006051600000) .
7. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-232194-S37696991442006051600000) .
8. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the oil pan. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-232194-S40320665632006051600000) and «OIL PAN»(ref-232194-S23630703092006051600000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Remove the oil level indictor.
4. Remove the 2 bolts and the oil level indicator tube. To install, tighten to 10 Nm (89 lb-in).
5. Remove and discard the oil level indicator tube O-ring seal.
6. To install, reverse the removal procedure. Lubricate a new O-ring seal with clean engine oil.

Scheme 44

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Remove the oil drain plug and drain the engine oil. To install, tighten to 28 Nm (21 lb-ft).
4. Remove and discard the oil filter. To install, tighten 3/4 of a turn after the filter gasket makes contact with the oil filter adapter.
5. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .
6. Disconnect the 2 coolant hoses from the oil cooler.
7. Disconnect the oil pressure sender electrical connector.
8. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
9. Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler. Inspect the oil cooler. To install, tighten to 34 Nm (25 lb-ft).
10. To install, reverse the removal procedure.
11. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .
12. Fill the engine with clean engine oil.