Engine Mechanical - 2.5L - (Except Hybrid): Component Locations

Special Tool(s)

SPECIAL TOOL REFERENCE CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Timing Peg, Crankshaft TDC 303-507

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Scheme 151: Special Tool(s)

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Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.
Remove the 4 bolts and the balancer unit.
Remove the adjustment shims from the seat faces of the balancer unit.
Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft).
Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg.
Position the Dial Indicator Gauge with Holding Fixture as shown. 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 balancer unit. 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.
Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit. ADJUSTMENT SHIM SELECTION TABLE Backlash mm (in) Selection shim (No.) Shim thickness mm (in) 0.516-0.528 (0.0203-0.0207) 15 1.15 (0.0452) 0.502-0.514 (0.0197-0.0202) 16 1.16 (0.0456) 0.489-0.500 (0.0192-0.0196) 17 1.17 (0.0460) 0.475-0.487 (0.0187-0.0191) 18 1.18 (0.0464) 0.462-0.473 (0.0181-0.0186) 19 1.19 (0.0468) 0.448-0.460 (0.0176-0.0181) 20 1.20 (0.0472) 0.435-0.446 (0.0171-0.0175) 21 1.21 (0.0476) 0.421-0.433 (0.0165-0.0170) 22 1.22 (0.0480) 0.408-0.419 (0.0160-0.0164) 23 1.23 (0.0484) 0.394-0.406 (0.0155-0.0159) 24 1.24 (0.0488) 0.381-0.392 (0.0150-0.0154) 25 1.25 (0.492) 0.367-0.379 (0.0144-0.0149) 26 1.26 (0.0496) 0.354-0.365 (0.0139-0.0143) 27 1.27 (0.0499) 0.340-0.352 (0.0133-0.0138) 28 1.28 (0.0503) 0.327-0.338 (0.0128-0.0133) 29 1.29 (0.0507) 0.313-0.325 (0.0123-0.0127) 30 1.30 (0.0511) 0.300-0.311 (0.0118-0.0122) 31 1.31 (0.0515) 0.286-0.298 (0.0112-0.0117) 32 1.32 (0.0519) 0.272-0.284 (0.0107-0.0111) 33 1.33 (0.0523) 0.259-0.271 (0.0101-0.0106) 34 1.34 (0.0527) 0.245-0.257 (0.0096-0.0101) 35 1.35 (0.0531) 0.232-.0243 (0.0091-0.0095) 36 1.36 (0.535) 0.218-0.230 (0.0085-0.0090) 37 1.37 (0.539) 0.205-.0216 (0.0080-0.0085) 38 1.38 (0.0543) 0.191-0.203 (0.0075-0.0079) 39 1.39 (0.0547) 0.178-0.189 (0.0070-0.0074) 40 1.40 (0.0551) 0.164-0.176 (0.0064-0.0069) 41 1.41 (0.0555) 0.151-0.162 (0.0059-0.0063) 42 1.42 (0.0559) 0.137-0.149 (0.0053-0.0058) 43 1.43 (0.0562) 0.124-0.135 (0.0048-0.0053) 44 1.44 (0.0566) 0.110-0.122 (0.0043-0.0048) 45 1.45 (0.0570) 0.097-0.108 (0.0038-0.0042) 46 1.46 (0.0574) 0.083-0.095 (0.0032-0.0037) 47 1.47 (0.0578) 0.070-0.081 (0.0027-0.0031) 48 1.48 (0.0582) 0.056-0.068 (0.0022-0.0026) 49 1.49 (0.0586) 0.043-0.054 (0.0016-0.0021) 50 (master) 1.50 (0.0590) 0.029-0.041 (0.0011-0.0016) 51 1.51 (0.0594) 0.015-0.027 (0.0005-0.0010) 52 1.52 (0.0598) 0.002-0.014 (0.00007-0.0005) 53 1.53 (0.0602) 0.000-0.000 (0.0000-0.0000) 54 1.54 (0.0606)
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft).
Position the Dial Indicator Gauge with Holding Fixture as shown. 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 balancer unit. 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. If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.

SPECIAL TOOL REFERENCE CHART Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Timing Peg, Crankshaft TDC 303-507 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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Scheme 156: Special Tool(s)

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SPECIAL TOOL REFERENCE CHART Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

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Scheme 159: Special Tool(s)

SPECIAL TOOL REFERENCE CHART Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

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Scheme 160: Special Tool(s)

SPECIAL TOOL REFERENCE CHART Aligner, Crankshaft Sensor 303-1417 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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Scheme 161: Special Tool(s)

SPECIAL TOOL REFERENCE CHART Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

SPECIAL TOOL REFERENCE CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

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Scheme 162: Special Tool(s)

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SPECIAL TOOL REFERENCE CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

SPECIAL TOOL REFERENCE CHART Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

SPECIAL TOOL REFERENCE CHART Support Bar, Engine 303-F072

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Scheme 165: Special Tool(s)

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Item	Part Number	Description
1	W710824	Engine mount bracket bolt
2	N807144	Engine mount bracket nut (3 required)
3	6A094	Engine mount bracket
4	W500233	Engine mount bolt (3 required)
5	6068	Engine mount

ITEM DESCRIPTION

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Scheme 167: Removal and Installation

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
Install the Engine Support Bar.
Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
Use the Engine Support Bar to raise the engine 25 mm (0.98 in).
Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 Nm (85 lb-ft).
Remove the 3 bolts and the engine mount. To install, tighten to 55 Nm (41 lb-ft).
To install, reverse the removal procedure.

SPECIAL TOOL REFERENCE CHART Disconnect Tool, Transmission Cooler Line 307-569 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Remover, Halfshaft Oil Seal 308-428 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

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Scheme 168: Special Tool(s)

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WARNING

Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.5L»(ref-344098) .
Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
Drain the engine oil. Install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
Remove the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-344113) .
Remove the bolts and the lateral support crossmember.
Remove the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
Remove the 2 intermediate shaft bearing retainer nuts.
Remove the intermediate shaft.
Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(ref-344110) .
Press the locking tab to release the generator air duct and remove.
Remove the drain plug and drain the transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-344057) . All-Wheel Drive (AWD) vehicles
Drain the Power Transfer Unit (PTU). For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-344082) .
Index the driveshaft to the yoke and remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire. All vehicles
If equipped, remove the bolt and ground eyelet.
Disconnect the transaxle electrical connector.
Detach the wiring harness retainer from the transaxle stud bolt.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
Remove the 2 secondary latches from the transaxle fluid cooler tubes.
Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown).
Remove the Power Distribution Box (PDB) cover.
Remove the nut and disconnect the cable from the PDB.
Disconnect the electrical connector from the PDB.
Remove the bolt and the ground strap.
Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.
Disconnect the shift cable from the transaxle manual lever.
Pinch the 2 tabs and remove the transmission shift cable from the bracket.
Detach the shift cable pin-type retainer and position the shift cable aside.
If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
Disconnect the upper radiator hose.
Detach the heater hose support strap from the stud.
Disconnect the heater hoses from the heater core.
Disconnect the vacuum supply tube and position aside.
Disconnect the fuel vapor return tube. Detach the fuel vapor tube retainer from the wire harness.
Disconnect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
Disconnect the PCM electrical connector and the wire harness retainer.
Disconnect the engine control harness electrical connector.
Disconnect the generator electrical connector and the 2 retainers.
Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire. Detach the wire harness retainer.
Disconnect the lower radiator hose from the radiator.
Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
Remove the rear nut and the engine support crossmember. Discard the nut.
If equipped, remove the 3 bolts and the dampener.
Remove the 2 transaxle-to-engine bolts.
Remove the 2 transaxle-to-engine bolts. AWD vehicles
Remove the 4 PTU bracket-to-engine bolts.
Remove the PTU bracket-to-engine bolt.
Remove the 2 PTU bracket-to-PTU bolts and remove the bracket. All vehicles
If equipped, remove the spin on engine oil filter.
If equipped, remove the oil filter element. For additional information, refer to «OIL FILTER ELEMENT»(ref-344116-S36613748902009101600000) .
Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
Remove the engine mount bracket bolt.
Remove the 3 nuts and the engine mount bracket.
Remove the bolt from the transaxle rear mount.
Remove the bolt from the LH transaxle mount.
Lower the engine and transaxle from the vehicle.
Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
Remove the nut and the ground wire.
Remove the 2 stud bolts and remove the starter.
Remove the starter motor isolator. AWD vehicles
Detach the PTU vent hose retainer.
Remove the LH lower PTU bolt.
Remove the 3 RH PTU bolts and the PTU.
Remove the 3 bolts and the PTU heat shield.
Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles
Remove and discard the 4 torque converter nuts.
Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.

WARNING

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.5L»(ref-344098) .
Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
Remove the LH half shaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-344113) .
Remove the 4 bolts and the lateral support crossmember.
Remove the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(ref-344110) .
Press the locking tabs to release the generator air duct and remove.
If equipped, remove the bolt and ground eyelet.
Remove the Power Distribution Box (PDB) cover.
Remove the nut and disconnect the cable from the PDB.
Disconnect the electrical connector from the PDB.
Remove the bolt and the ground strap.
Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.
Position the clutch hydraulic line aside. Remove the clutch hydraulic line bracket-to-transaxle bolt. Disconnect the clutch hydraulic line from the clutch slave cylinder. Plug the hydraulic line. Position the clutch hydraulic line aside.
Disconnect the Vehicle Speed Sensor (VSS) electrical connector and the 2 pin-type retainers.
Detach the 2 wiring harness retainers and disconnect the reversing lamp indicator switch electrical connector.
Disconnect the shift cables.
Remove the 3 shift cable bracket bolts. Position the bracket aside.
If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
Disconnect the upper radiator hose.
Detach the heater hose support strap from the stud.
Disconnect the heater hoses from the heater core.
Disconnect the vacuum supply tube and position aside.
Disconnect the fuel vapor return tube. Detach the fuel vapor tube retainer from the wire harness.
Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
Disconnect the PCM electrical connector and the wire harness retainer.
Disconnect the engine control harness electrical connector.
Disconnect the generator electrical connector and the 2 retainers.
Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
Disconnect the lower radiator hose from the radiator.
Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
Remove the rear nut and the engine support crossmember. Discard the nut.
Remove the 2 transaxle-to-engine bolts.
Remove the 2 engine-to-transaxle bolts.
If equipped, remove the spin on engine oil filter.
If equipped, remove the oil filter element. For additional information, refer to «OIL FILTER ELEMENT»(ref-344116-S36613748902009101600000) .
Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
Remove the engine mount bracket bolt.
Remove the nuts and the engine mount bracket.
Remove the bolt from the transaxle rear mount.
Remove bolt from the LH transaxle mount.
Lower the engine and transaxle from the vehicle.
Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
Remove the nut and the ground wire.
Remove the 2 stud bolts and remove the starter.
Remove the starter motor isolator.
Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
Remove the remaining 5 engine-to-transaxle bolts and separate the engine and transaxle.

SPECIAL TOOL REFERENCE CHART Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Engine Stand 014-00232 or equivalent Installer, Connecting Rod 303-462 (T94P-6136-AH) Remover, Oil Seal 303-409 (T92C-6700-CH) Timing Peg, Crankshaft TDC 303-507

Scheme 231

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. 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. Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Note. For additional information, refer to the exploded views under the Engine Assembly procedure.

Vehicles with manual transaxle

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Remove the bolts, clutch pressure plate and clutch disc.
Remove the bolts and the flywheel. Vehicles with automatic transaxle
Remove the bolts and the flexplate. All vehicles
Mount the engine on a suitable stand.
Disconnect the Crankshaft Position (CKP) sensor electrical connector. Detach the wiring harness-to-engine retainer.
Disconnect the generator electrical connection and the 2 wiring harness retainers.
Remove the nut and the generator wiring harness.
Remove the 2 nuts, 1 bolt and the generator.
Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
Remove the 4 exhaust manifold heat shield bolts and the heat shield.
Remove and discard the 7 exhaust manifold nuts.
Remove the exhaust manifold and discard the exhaust manifold gasket.
Remove and discard the 7 exhaust manifold studs.
Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
Remove the 2 bolts and the accessory drive belt tensioner.
Loosen the bolt and remove the accessory drive belt idler pulley.
Remove the 2 bolts and the accessory drive belt idler pulley and bracket.
Remove the 3 bolts and the coolant pump pulley.
Remove the bolts and the coolant pump.
Remove the 3 bolts and the thermostat housing assembly.
Remove the coolant tube retainer from the intake manifold.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
Remove the 4 bolts and the oil filter adapter. Discard the gasket.
If equipped, remove the bolt and capacitor.
Disconnect the Variable Camshaft Timing (VCT) electrical connector.
Detach the wiring harness retainers from the RH side valve cover stud bolts.
Disconnect the crankcase vent hose from the valve cover.
Detach the wiring harness retainers from the LH side valve cover stud bolts.
Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.
Disconnect the EGR valve electrical connector.
Disconnect the Knock Sensor (KS) and detach the 2 wiring harness retainers.
Detach all the wiring harness retainers from the intake manifold.
Disconnect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.
Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
Disconnect the radio capacitor electrical connector.
Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers and remove the wiring harness assembly.
Remove the fuel rail insulator.
Remove the nut and the radio capacitor.
Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.
Remove the 8 bolts (3 shown) and position the intake manifold aside.
Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
Remove the EGR tube.
Disconnect the coolant hose.
Disconnect and remove the coolant hose.
Disconnect and remove 2 the coolant hoses.
Remove the bolt and the KS.
Remove the 8 bolts and the crankcase vent oil separator.
If equipped, remove the block heater.
Remove the oil level indicator.
Remove the 4 bolts and the 4 coil-on-plugs.
Remove the spark plugs and the CHT sensor.
Remove the 12 retainers and the valve cover.
Remove the bolts and the CKP sensor.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Remove the engine plug bolt.
Install the Crankshaft TDC Timing Peg.
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
Remove the 22 bolts and the engine front cover.
Compress the timing chain tensioner in the following sequence. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a paper clip into the hole to retain the tensioner.
Remove the 2 bolts and the timing chain tensioner.
Remove the RH timing chain guide.
Remove the timing chain.
Remove the bolts and the LH timing chain guide.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.
Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring Remove the tensioner and the 2 shoulder bolts.
Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
Remove the bolt and the VCT solenoid.
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
Remove the camshafts from the engine. Loosen the camshaft bearing 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.
Remove the cylinder head. Remove and discard the cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
Remove the cylinder head alignment dowels.
Remove the bolts and the oil pan.
Remove the bolts and the rear crankshaft seal.
Remove the bolts, oil pump pickup tube and gasket. Discard the gasket.
Remove the bolts and the oil pump.
Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC.
Remove the 4 bolts and the balancer unit.
Remove the Crankshaft TDC Timing Peg.
Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer' s instructions.
Remove the connecting rod cap bolts and cap.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
Remove the bolts in the sequence shown. Remove the main bearing beam. Discard the bolts.
Remove the crankshaft from the engine block.
Remove the main bearings from the main bearing beam.
Remove the main bearings from the cylinder block.
Remove the 4 oil squirts.
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .

SPECIAL TOOL REFERENCE CHART Aligner, Clutch Disc 308-006 (T71P-7137-H) Aligner, Crankshaft Sensor 303-1417 Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Heavy Duty Floor Crane 014-00071 or equivalent Holding Tool, Crankshaft Damper 303-1416 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Connecting Rod 303-462 (T94P-6136-AH) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 289

SPECIAL TOOL REFERENCE CHART Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, PTO Driven Gear Oil Seal 308-429 Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 290

Scheme 290: Special Tool(s)

SPECIAL TOOL REFERENCE CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Engine Mechanical - 2.5L - (Except Hybrid): Component Locations Ford Escape II