Engine Mechanical - 2.5L - (Hybrid): Removal & Installation Ford Escape II

Removal

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .
3. Disconnect the crankcase vent hose from the valve cover.
4. Remove the 4 engine cover studs.
5. Detach the 3 wire harness retainers from the valve cover stud bolts.
6. Disconnect the Camshaft Position (CMP) sensor electrical connector.
7. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
8. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
9. Remove the oil level indicator.
10. Remove the 14 valve cover retainers, the valve cover and gasket.

Scheme 619

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown.
3. Install the valve cover, gasket and retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Install the oil level indicator.
5. Connect the VCT solenoid electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the CMP sensor electrical connector.
8. Attach the 3 wire harness retainers to the valve cover stud bolts.
9. Install the 4 engine cover studs.
10. Connect the crankcase vent hose to the valve cover.
11. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .

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.

Scheme 620

Scheme 621

Scheme 622

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-344118-S41440364292009101600000) .
5. 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.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. 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.

Scheme 623

Scheme 624

Scheme 625

1. Install a new diamond washer.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Remove the 6 mm x 18 mm bolt.
6. Remove the Crankshaft TDC Timing Peg.
7. Remove the Camshaft Alignment Plate.
8. Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft TDC Timing Peg.
10. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
11. 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 by repeating this procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the special tool, the engine valve timing must be corrected by repeating this procedure.
13. Remove the Camshaft Alignment Plate.
14. Remove the 6 mm x 18 mm bolt.
15. Remove the Crankshaft TDC Timing Peg.
16. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
17. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
18. Install the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
19. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-344118-S41440364292009101600000) .

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 or 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.

1. Remove the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-344118-S26359988902009101600000) and «CRANKSHAFT PULLEY»(ref-344118-S03475056672009101600000) .
2. Using the Oil Seal Remover, remove the crankshaft front seal.

Installation

1. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-344118-S26359988902009101600000) and «CRANKSHAFT PULLEY»(ref-344118-S03475056672009101600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the engine. For additional information, refer to «ENGINE»(ref-344118-S38850329502009101600000) .
3. Remove the 6 bolts and the flywheel.

Scheme 626

1. Install the flywheel and tighten the bolts in the sequence shown in the following 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).
2. Install the engine. For additional information, refer to «ENGINE»(ref-344118-S38850329502009101600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the flywheel. For additional information, refer to «FLYWHEEL»(ref-344118-S33165793842009101600000) .
3. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
4. Remove the 17 bolts and the oil pan.
5. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

Scheme 627

Scheme 628

Scheme 629

Scheme 630

1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear oil seal with retainer plate and bolts. 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.
5. Install the oil pan. Install the 2 oil pan bolts finger-tight.
6. Install the 4 bolts. Tighten to 10 Nm (89 lb-in).
7. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
8. Install the flywheel. For additional information, refer to «FLYWHEEL»(ref-344118-S33165793842009101600000) .
9. Fill the engine with clean engine oil.

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.

Scheme 631

Scheme 632

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
3. Remove the crankshaft pulley. For additional information refer to «CRANKSHAFT PULLEY»(ref-344118-S03475056672009101600000) .
4. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-344118-S28955722972009101600000) .
5. Using the Oil Seal Remover, remove the crankshaft front seal.
6. Remove the 3 bolts and the coolant pump pulley.
7. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
8. Remove the 2 bolts and the CKP sensor.
9. Remove the bolts and the engine front cover.

Scheme 633

Scheme 634

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. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
5. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (177 lb-in).
6. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-344118-S28955722972009101600000) .
7. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-344118-S03475056672009101600000) .
8. 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.
9. Install the CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
10. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
11. Connect the CKP sensor electrical connector.
12. Remove the 6 mm x 18 mm bolt.
13. Install the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .

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 or 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.

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

1. With the vehicle 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-344118-S27094053322009101600000) .
3. 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.
4. Remove the 2 bolts and timing chain tensioner.
5. Remove the timing chain tensioner arm.
6. Remove the timing chain.
7. Remove the 2 bolts and the timing chain guide.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
9. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.

Scheme 640

Scheme 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the timing chain guide and the 2 bolts. To install, tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the timing chain tensioner arm. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
5. Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.
7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
9. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
10. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
11. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344118-S27094053322009101600000) .

Scheme 646

ITEM DESCRIPTION CHART

Removal and Installation

1. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(ref-344103) .
2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. To install, tighten to 17 Nm (150 lb-in).
3. To install, reverse the removal procedure.

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. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .
3. Depower the vehicle High Voltage Traction Battery (HVTB) electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(ref-344108) .
4. Remove the degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-344114) .
5. Remove the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(ref-344097) .
6. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(ref-344103) .
7. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-344118-S39929543302009101600000) .
8. Remove the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
9. Remove the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
10. 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.
11. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
12. Remove the engine plug bolt.
13. Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
14. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
15. Remove the lower front cover timing hole plug from the engine front cover.
16. Remove the upper front cover timing hole plug from the engine front cover.
17. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
18. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
19. Remove the Camshaft Alignment Plate.
20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
21. Remove the timing chain from the camshaft phaser and sprocket.
22. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
23. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
24. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

Scheme 656

Scheme 657

Scheme 658

1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. 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 turn at a time, until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the camshaft phaser and sprocket.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the bolt. Tighten to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper front cover timing hole plug. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug. Install the plug and tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
15. Install the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-344055) .
16. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(ref-344103) .
17. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-344118-S41440364292009101600000) .
18. Install the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(ref-344097) .
19. Install the degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-344114) .
20. Repower the vehicle HVTB electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(ref-344108) .
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-344091) .

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. Do not rotate the camshafts or crankshaft unless instructed to do so in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons.

Scheme 659

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
3. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(ref-344104) .
4. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-344118-S39929543302009101600000) .
5. 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.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
10. Remove the lower timing hole plug from the engine front cover.
11. Remove the upper timing hole plug from the engine front cover.
12. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
13. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
14. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
15. Remove the Camshaft Alignment Plate.
16. Remove the timing chain from the camshaft phaser and sprocket.
17. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
18. Remove the intake camshaft from the engine. Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the intake camshaft.
19. Mark the camshaft phaser and sprocket and the camshaft for reference during installation.
20. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

Scheme 660

1. Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the intake camshaft bearing cap bolts until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the camshaft phaser and sprocket.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-344112) .
15. Install the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(ref-344104) .

Scheme 661

ITEM DESCRIPTION CHART

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

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.

Scheme 662

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-344118-S03276802172009101600000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, 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 Valve Spring Compressors, 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.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-344118-S03276802172009101600000) .

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.

Scheme 663

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-344118-S03276802172009101600000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, 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.
7. Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seal.

Scheme 664

Scheme 665

1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. Using the Valve Spring Compressors, 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.
5. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(ref-344121) .
6. Repeat the appropriate removal and installation steps for all of the other cylinders.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-344118-S03276802172009101600000) .

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-344118-S03276802172009101600000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

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 or 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.

Scheme 666

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-344122) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-344114) .
4. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-344118-S22343797832009101600000) .
5. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(ref-344103) .
6. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344118-S30943469632009101600000) .
7. Remove the Camshaft Alignment Plate.
8. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
9. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
10. Remove the valve tappets.
11. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-344060) .
12. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
13. Disconnect the EGR valve electrical connector.
14. Disconnect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose from the engine coolant outlet and the EGR valve.
15. Remove the bolts and the cylinder head. Discard the bolts and the cylinder head gasket.

Scheme 667

Scheme 668

1. 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.
2. 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) .
3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new cylinder head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 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.
7. Connect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose to the engine coolant outlet and the EGR valve.
8. Connect the EGR valve electrical connector.
9. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-344061) .
10. Install the valve tappets in their original positions.
11. 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 turn at a time, until finger-tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
12. Install the Camshaft Alignment Plate.
13. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-344118-S30943469632009101600000) .
14. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(ref-344103) .
15. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-344118-S22343797832009101600000) .
16. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-344114) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Loosen the oil filter drain plug.
3. Using a cup-style oil filter wrench, loosen the oil filter cover one turn.
4. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter. Remove and discard the oil filter drain plug O-ring seal.
5. Remove the oil filter cover and oil filter element. Discard the oil filter element. Remove and discard the oil filter cover O-ring seal.

1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter.
2. Install a new oil filter cover O-ring seal.
3. Install a new oil filter element and the oil filter cover. Using a cup-style oil wrench, tighten to 33 Nm (24 lb-ft).
4. Install a new oil filter drain plug O-ring seal.
5. Install the oil filter drain plug. Tighten to 10 Nm (89 lb-in).

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the pin-type retainer (not shown), 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. If equipped, remove the oil filter element. For additional information, refer to «OIL FILTER ELEMENT»(ref-344118-S41966454352009101600000) .
5. If equipped, remove the spin-on oil filter. To install, 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.
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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the pin-type retainer, the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
5. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Drain the engine oil, then install the drain plug. Tighten to 28 Nm (21 lb-ft).
3. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344118-S27094053322009101600000) .
4. Remove the 4 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.

Scheme 669

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.
3. Position the oil pan and install the 2 rear oil pan bolts finger-tight.
4. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
5. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
6. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
7. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-344118-S27094053322009101600000) .
8. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a To install, tighten to 10 Nm (89 lb-in). hoist. For additional information, refer to «JACKING & LIFTING»(ref-344051) .
2. Remove the oil pan. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-344118-S21745582342009101600000) and «OIL PAN»(ref-344118-S24543244822009101600000) .
3. Removal and Installation 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.