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

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

Scheme 291

ITEM DESCRIPTION

Scheme 292

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION - GASOLINE MODELS .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. are connected in series with the fuel pressure sensor.
5. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

Intake Manifold

Intake Manifold (View 1 of 2)

Scheme 293

ITEM DESCRIPTION

Intake Manifold (View 2 of 2)

Scheme 294

ITEM DESCRIPTION

Scheme 295

Scheme 296

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 2.5L»(ref-344120) .
3. Disconnect the vacuum supply hose. Depress the quick release locking ring. Pull the vacuum hose out of the quick release fitting.
4. Disconnect the fuel vapor return hose from the intake manifold.
5. Disconnect the Manifold Absolute Pressure (MAP) electrical connector.
6. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
7. Disconnect the electronic throttle control electrical connector.
8. Disconnect the Knock Sensor (KS) electrical connector. Detach the wire harness pin-type retainer.
9. Detach the heater hose pin-type retainer.
10. Detach all wiring harness pin-type retainers from the intake manifold and position the wiring harness aside.
11. Loosen the clamp and disconnect Air Cleaner (ACL) outlet pipe from the Throttle Body (TB). To install, tighten to 4 Nm (35 lb-in).
12. Remove the intake manifold lower bolt. To install, tighten to 18 Nm (159 lb-in).
13. Remove the 6 bolts and position the intake manifold aside to access the crankcase vent oil separator tube and the EGR tube. To install, tighten to 18 Nm (159 lb-in).
14. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
15. Remove the EGR tube. To install, tighten to 55 Nm (41 lb-ft).
16. Remove the intake manifold and gaskets.
17. To install, reverse the removal procedure. Inspect and install new intake manifold gaskets if necessary.

Material

ITEM SPECIFICATION

Valve Cover (View 1 of 2)

Scheme 297

ITEM DESCRIPTION

Valve Cover (2 of 2)

Scheme 298

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General Equipment

GENERAL EQUIPMENT REFERENCE

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GENERAL EQUIPMENT REFERENCE

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Scheme 299

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GENERAL EQUIPMENT REFERENCE

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GENERAL EQUIPMENT REFERENCE

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Scheme 300

ITEM DESCRIPTION

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Scheme 301

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344116-S20770325452009101600000) .
3. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 4 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.
6. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
7. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner.
8. Remove the chain from the oil pump sprocket.
9. Remove the bolt and oil pump sprocket.
10. Remove the 4 bolts and the oil pump.

Scheme 302

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Scheme 306

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Clean all mating surfaces with metal surface prep.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
11. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344116-S20770325452009101600000) .
13. Fill the engine with clean engine oil.

Scheme 307

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Scheme 308

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GENERAL EQUIPMENT REFERENCE

ITEM SPECIFICATION

Lower Engine Block (View 1)

Scheme 310

ITEM DESCRIPTION

Lower Engine Block (View 2)

Scheme 311

ITEM DESCRIPTION

Front Engine Block

Scheme 312

ITEM DESCRIPTION

Cylinder Head

Scheme 313

ITEM DESCRIPTION

Intake Manifold

Scheme 314

ITEM DESCRIPTION

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 may 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 .

All vehicles

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1. Install the 4 oil squirts. Tighten to 4 Nm (35 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.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown 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. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: 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. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then 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. Tighten the bolts in the sequence shown 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 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the 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.
20. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
21. 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).
22. Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. 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.
24. 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).
25. Remove the Crankshaft TDC Timing Peg.
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. 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.
28. 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. 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 procedure. For additional information, refer to «BALANCE SHAFT BACKLASH»(ref-344116-S03119375072009101600000) procedure.
29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
30. Remove the engine plug bolt.
31. Install the Crankshaft TDC Timing Peg.
32. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
33. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
35. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
36. Clean and inspect all mating surfaces.
37. 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.
38. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
39. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
40. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
41. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. 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.
42. Apply silicone gasket and sealant to the locations shown.
43. Install a new head gasket.
44. Install the cylinder head and 10 new 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 (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
45. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
46. Install the VCT system oil filter and the plug in the intake camshaft thrust cap. Tighten to 17 Nm (150 lb-in).
47. Install the Variable Camshaft Timing (VCT) solenoid and the bolt. Tighten to 10 Nm (89 lb-in).
48. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
49. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
50. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
51. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
52. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
54. Install the LH timing chain guide and the bolts. Tighten to 10 Nm (89 lb-in).
55. Install the timing chain.
56. Install the RH timing chain guide. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
57. Using the edge of a vise, compress the timing chain tensioner plunger.
58. Using a small pick, push back and hold the ratchet mechanism.
59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
61. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
63. Clean and inspect the mounting surfaces of the engine and the front cover.
64. 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.
65. 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).
66. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
68. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
69. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool 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).
70. Remove the 6 mm x 18 mm bolt.
71. Remove the Crankshaft TDC Timing Peg.
72. Remove the Camshaft Alignment Plate.
73. Turn the crankshaft clockwise one and three-fourths turns.
74. Install the Crankshaft TDC Timing Peg.
75. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
76. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
77. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
78. Remove the Camshaft Alignment Plate.
79. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
80. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
81. Remove the 6 mm x 18 mm bolt.
82. Remove the Crankshaft TDC Timing Peg.
83. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
84. Clean the valve cover gasket surface with metal surface cleaner.
85. Apply silicone gasket and sealant to the locations shown.
86. Install the valve cover. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
87. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (106 lb-in). Tighten the spark plugs to 12 Nm (106 lb-in).
88. Install the 4 coil-on-plugs and the 4 bolts. Tighten to 8 Nm (71 lb-in).
89. Install the oil level indicator.
90. If equipped, install the block heater. Tighten to 40 Nm (30 lb-ft).
91. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
92. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
93. Install the 2 coolant hoses.
94. Install the coolant hose.
95. Install the coolant hose.
96. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
97. Position the intake manifold and connect the crankcase vent oil separator tube.
98. Install the intake manifold gaskets, intake manifold and the 8 bolts. Tighten to 18 Nm (159 lb-in).
99. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
100. Install the fuel rail with the fuel injectors as an assembly and the 2 stud bolts. Tighten to 23 Nm (17 lb-ft).
101. Install the radio capacitor and nut. Tighten to 10 Nm (89 lb-in).
102. Install the fuel rail insulator.
103. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
104. Connect the radio capacitor electrical connector.
105. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
106. Connect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.
107. Attach all the wiring harness retainer to the intake manifold.
108. Connect the KS and attach the 2 wiring harness retainers.
109. Connect the EGR valve electrical connector.
110. Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.
111. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
112. Attach the wiring harness retainers to the LH side valve cover stud bolts.
113. Connect the crankcase vent hose to the valve cover.
114. Attach the wiring harness retainers to the RH side valve cover stud bolts.
115. Connect the VCT electrical connector.
116. If removed, install the capacitor and bolt. Tighten to 20 Nm (177 lb-in).
117. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
118. Connect the Engine Oil Pressure (EOP) switch electrical connector.
119. Install the coolant tube retainer to the intake manifold.
120. Install the thermostat housing and bolts. Tighten to 10 Nm (89 lb-in).
121. Install the coolant pump and bolts. Tighten to 10 Nm (89 lb-in).
122. Install the 3 coolant pump pulley and bolts. Tighten to 20 Nm (177 lb-in).
123. Install the accessory drive belt idler pulley and bracket and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
124. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
125. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
126. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 Nm (150 lb-in).
127. Install the new exhaust manifold gasket on the engine.
128. Position the exhaust manifold and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages: Stage 1: Tighten to 48 Nm (35 lb-ft). Stage 2: Tighten to 48 Nm (35 lb-ft).
129. Install the exhaust manifold heat shield and the 4 bolts. Tighten to 10 Nm (89 lb-in).
130. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
131. Install the generator, 2 nuts and 1 bolt. Tighten to 47 Nm (35 lb-ft).
132. Connect the generator electrical connection and install the nut. Tighten to 6 Nm (53 lb-in).
133. Connect the generator electrical connection and attach the 2 wiring harness retainers.
134. Connect the CKP sensor electrical connector. Attach the wiring harness-to-engine retainer.
135. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand. Vehicles with automatic transaxle
136. Install the flexplate and the bolts. 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 (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft). Vehicles with manual transaxle
137. Install the flywheel and the bolts. 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 (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
138. Lubricate the transaxle input shaft pilot bearing with front axle grease.
139. Using the Clutch Disk Aligner, position the clutch disc on the flywheel.
140. Position the clutch pressure plate and install the bolts. Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.

ITEM SPECIFICATION

All vehicles

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1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
2. Install the 4 new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
3. Using the Powertrain Lift and Universal Adapter Brackets, position the engine and transaxle onto the Powertrain Lift. All-Wheel Drive (AWD) vehicles
4. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
5. Install the PTU heat shield and the 3 bolts. Tighten to 11 Nm (97 lb-in).
6. Install the Power Transfer Unit (PTU) and the 3 RH PTU bolts. Tighten to 70 Nm (52 lb-ft).
7. Install the LH lower PTU bolt. Tighten to 48 Nm (35 lb-ft).
8. Attach the PTU vent hose. All vehicles
9. Install the starter motor isolator.
10. Install the starter motor and the 2 stud bolts. Tighten to 35 Nm (26 lb-ft).
11. Install the ground wire and the nut. Tighten to 25 Nm (18 lb-ft).
12. Install the starter motor harness connectors. Install the starter motor solenoid battery nut. Tighten to 12 Nm (106 lb-in). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
13. Raise the engine and transaxle into the vehicle.
14. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
15. Install the bolt in the rear transaxle mount. Tighten to 115 Nm (85 lb-ft).
16. Install the engine mount bracket and nuts. Tighten to 115 Nm (85 lb-ft).
17. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
18. If equipped, install a new oil filter element. For additional information, refer to «OIL FILTER ELEMENT»(ref-344116-S36613748902009101600000) .
19. If equipped, install a new spin on engine oil filter. Lubricate the spin on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. AWD vehicles
20. Install the PTU bracket and the 2 PTU bracket-to-PTU bolts. Tighten to 45 Nm (33 lb-ft).
21. Install the PTU bracket-to-engine bolt. Tighten to 40 Nm (30 lb-ft).
22. Install the 4 PTU bracket-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
23. Install a new intermediate shaft seal and deflector. For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-344082) .
24. If equipped, install the dampener and the 3 bolts. Tighten to 40 Nm (30 lb-ft).
25. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
26. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
27. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
28. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
29. Connect the lower radiator hose to the radiator.
30. Install the A/C compressor and connect the A/C compressor electrical connector. Attach the wire harness retainer. Tighten the bolts to 25 Nm (18 lb-ft).
31. Attach the 2 retainers and connect the generator electrical connector.
32. Connect the engine control harness electrical connector.
33. Connect the PCM electrical connector and attach the wire harness retainer.
34. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
35. Connect the fuel vapor return tube. Attach the fuel vapor tube retainer to the wire harness.
36. Connect the vacuum supply tube.
37. Connect the heater hoses to the heater core.
38. Attach the heater hose support strap to the stud.
39. Connect the upper radiator hose.
40. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
41. Attach the shift cable pin-type retainer.
42. Attach the shift cable to the shift cable bracket.
43. Connect the shift cable to the transaxle manual lever.
44. Attach the 2 wiring harness retainers to the battery tray bracket.
45. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
46. Connect the electrical connector to the Power Distribution Box (PDB).
47. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (106 lb-in).
48. Install the PDB cover.
49. Connect the 2 transaxle fluid cooler tubes.
50. Install the 2 secondary latches to the transaxle fluid cooler tubes.
51. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
52. Attach the wiring harness retainer to the transaxle stud bolt.
53. Connect the transaxle electrical connector.
54. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in). AWD vehicles
55. Position the driveshaft to the PTU and install the 6 bolts. Tighten to 37 Nm (27 lb-ft). All vehicles
56. Install the generator air duct and make sure the tab is latched.
57. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(ref-344110) .
58. Install the intermediate shaft.
59. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 Nm (20 lb-ft).
60. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
61. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
62. Install the RH and LH half shafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
63. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
64. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.5L»(ref-344098) .
65. Fill the engine with clean engine oil.
66. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-344113) .
67. Check and fill the transmission fluid as necessary. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-344057) . AWD vehicles
68. Check and fill the PTU fluid as necessary. For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-344082) . All vehicles
69. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

ITEM SPECIFICATION

Scheme 344

Scheme 345

1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts.
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.
3. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
4. Install the starter motor isolator.
5. Install the starter motor and the 2 stud bolts. Tighten to 35 Nm (26 lb-ft).
6. Install the ground wire and the nut. Tighten to 25 Nm (18 lb-ft).
7. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 Nm (106 lb-in). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
8. Raise the engine and transaxle into the vehicle.
9. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
10. Install the bolt in the rear transaxle mount. Tighten 115 Nm (85 lb-ft).
11. Install the engine mount bracket and nuts. Tighten 115 Nm (85 lb-ft).
12. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
13. If equipped, install a new oil filter element. For additional information, refer to «OIL FILTER ELEMENT»(ref-344116-S36613748902009101600000) .
14. If equipped, install a new spin on engine oil filter. Lubricate the spin on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
15. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
16. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
17. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
18. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
19. Connect the lower radiator hose to the radiator.
20. Position the A/C compressor and install the 3 bolts. Tighten the bolts to 25 Nm (18 lb-ft). Connect the A/C compressor electrical connector. Attach the wire harness retainer.
21. Connect the generator electrical connector and attach the 2 retainers.
22. Connect the engine control harness electrical connector.
23. Connect the PCM electrical connector and attach the wire harness retainer.
24. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
25. Connect the fuel vapor return tube and retainer. Attach the fuel vapor tube retainer to the wire harness.
26. Connect the vacuum supply tube.
27. Connect the heater hoses to the heater core.
28. Attach the heater hose support strap to the stud.
29. Connect the upper radiator hose.
30. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
31. Install the shift cable bracket. Position the shift cable bracket. Install the 3 bolts. Tighten to 22 Nm (16 lb-ft).
32. Connect the shift cables.
33. Connect the reversing lamp indicator switch electrical connector and attach the 2 wiring harness retainers.
34. Connect the Vehicle Speed Sensor (VSS) electrical connector and attach the 2 pin-type retainers.
35. Connect the clutch hydraulic line. Position the clutch hydraulic line. Connect the clutch hydraulic line to the clutch slave cylinder. Tighten to 25 Nm (18 lb-ft). Install the clutch hydraulic line bracket-to-transaxle bolt. Tighten to 3 Nm (27 lb-in).
36. Position the wiring harness and attach the 2 wiring harness retainers to the battery tray bracket.
37. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
38. Connect the electrical connector to the Power Distribution Box (PDB).
39. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (106 lb-in).
40. Install the PDB cover.
41. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
42. Install the generator air duct and make sure the tab is latched.
43. Install the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(ref-344110) .
44. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
45. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
46. Install the LH halfshaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-344085) .
47. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
48. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 2.5L»(ref-344098) .
49. Fill the engine with clean engine oil.
50. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-344113) .
51. Bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-344059) .
52. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.