Engine - 2.0L and 2.3L: Removal & Installation Ford Focus I facelift

REMOVAL

All engines

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the cooling fan motor and shroud assembly. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
3. Remove the lower intake manifold bolt.
4. Remove the air cleaner outlet pipe. Loosen the clamps. Disconnect the vent tube and remove the outlet pipe.
5. Remove the accelerator snow shield. Detach the evaporative emissions hose pin-type retainer. Remove the screw and pin-type retainer. Remove the snow shield.
6. Disconnect the accelerator cable and speed control cable (if equipped). Disconnect the accelerator and speed control cable (if equipped) from the throttle body. Remove the 3 bolts and position the accelerator control cables and bracket aside.
7. Disconnect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
8. Disconnect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
9. Disconnect the fuel vapor return hose.
10. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
11. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
12. Detach the wiring harness pin-type retainer.
13. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
14. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
15. If equipped, disconnect the secondary air injection (AIR) vacuum supply hose.
16. Disconnect the swirl control valve electrical connector.
17. Remove the bolt and the oil level indicator tube.
18. Remove the 7 intake manifold bolts.
19. Disconnect the swirl valve electrical connectors and pin-type retainers.
20. Remove the 2 bolts and the oil level indicator tube.
21. Remove the 7 intake manifold bolts.
22. Raise the intake manifold enough to gain clearance to disconnect the knock sensor (KS) electrical connector.
23. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
24. Remove the exhaust gas recirculation (EGR) tube.

INSTALLATION

All engines

1. Inspect and install new intake manifold gaskets if necessary.
2. Install the EGR tube and tighten to 55 Nm (41 lb-ft).
3. Position the intake manifold and connect the PCV hose.
4. Connect the KS electrical connector.
5. Install the intake manifold and the 7 mounting bolts. Tighten to 18 Nm (13 lb-ft).
6. Install the oil level indicator tube and 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Connect the swirl valve electrical connectors and pin-type retainers.
8. Install the intake manifold and the 7 mounting bolts. Tighten to 18 Nm (13 lb-ft).
9. Install the oil level indicator tube and bolt. Tighten to 10 Nm (89 lb-in).
10. Connect the swirl control valve electrical connector.
11. If equipped, connect the AIR vacuum supply hose.
12. Install the lower intake manifold bolt. Tighten to 18 Nm (13 lb-ft).
13. Connect the MAP sensor electrical connector.
14. Connect the IMRC actuator electrical connector.
15. Attach the wiring harness pin-type retainer.
16. Connect the fuel rail pressure and temperature sensor vacuum hose.
17. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting.
18. Connect the fuel vapor return hose.
19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.
20. Connect the TP sensor electrical connector and wiring harness pin-type retainer.
21. Connect the accelerator cable and speed control cable (if equipped). Install the accelerator cable bracket and 3 bolts. Tighten to 10 Nm (89 lb-in). Connect the accelerator and speed control cable (if equipped) to the throttle body.
22. Install the accelerator control snow shield. Position the snow shield and tighten the retainer to 10 Nm (89 lb-in). Attach the evaporative emissions hose pin-type retainer.
23. Install the air cleaner outlet pipe. Tighten the clamps to 4 Nm (35 lb-in).
24. Install the cooling fan motor and shroud assembly. For additional information, refer to «ENGINE COOLING»(ref-278250) article.

Scheme 1

Scheme 2

All vehicles

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
2. Disconnect the camshaft position (CMP) sensor electrical connector.
3. Lift up the connector boot and disconnect the cylinder head temperature (CHT) sensor electrical connector.
4. Disconnect the ignition coil-on-plug electrical connectors.
5. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
6. Disconnect the breather tube from the valve cover.
7. Disconnect the fuel rail pressure and temperature sensor and the fuel injector electrical connectors. Detach the wiring harness retainers.
8. Remove the radio interference capacitor bracket bolt and position the bracket aside.
9. Disconnect the heated oxygen sensor (HO2S) electrical connector.
10. Detach all of the wiring harness retainers from the valve cover studs and position the harness aside.
11. Remove the 14 valve cover retainers, the valve cover and gasket. Discard the valve cover gasket.

All vehicles

1. Clean and inspect the sealing surfaces.
2. Install the valve cover, a new gasket and the 14 retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs.
4. Connect the HO2S electrical connector.
5. Position the radio interference capacitor bracket and install the bolt. Tighten to 10 Nm (89 lb-in).
6. Attach the wiring harness retainers. Connect the fuel rail pressure and temperature sensor and the fuel injectors electrical connectors.
7. Install the breather tube on the valve cover.
8. Install the ignition coils and the 4 ignition coil-to-valve cover bolts. Tighten to 10 Nm (89 lb-in).
9. Connect the ignition coil-on-plug electrical connectors.
10. Connect the CHT sensor electrical connector and install the connector boot. Tighten to 10 Nm (89 lb-in).
11. Connect the CMP sensor electrical connector.
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.

Scheme 3

Scheme 4

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
3. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-278254-S19664308962008012400000) .
4. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
5. Install the special tool in the slots on the rear of both camshafts.
6. Remove the engine plug bolt.
7. Install the special tool.
8. Assemble the special tools using 4 hardened washers in the locations shown.
9. Using the special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.

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 standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
4. Assemble the special tools using 4 hardened washers in the locations shown.
5. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
6. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
7. Remove the special tool.
8. Remove the special tool.
9. Turn the crankshaft clockwise 1 and 3/4 turns.
10. Install the special tool.
11. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
12. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
13. Install the special tool 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.
14. Remove the special tool.
15. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
16. Remove the special tool.
17. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
18. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
19. Install the valve cover. For additional information, refer to «Valve Cover»(ref-278254-S19664308962008012400000) .

1. Remove the crankshaft pulley. For additional information, refer to «Lower End Components - Exploded View»(ref-278254-S26585524732008012400000) and «Crankshaft Pulley»(ref-278254-S40379588202008012400000) .
2. Using the special tool, remove the crankshaft front oil seal.

1. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «Lower End Components - Exploded View»(ref-278254-S26585524732008012400000) and «Crankshaft Pulley»(ref-278254-S40379588202008012400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-278257) article.
3. Install the special tool and remove the 6 flexplate bolts and the flexplate.

1. Install the flexplate.
2. Install the special tool.
3. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
4. Install the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-278257) article.

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-278299) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-278298) article.
3. Install the special tool and remove the 6 bolts and the flywheel.

Note. Engine balancing is not required. Balance weights should not be installed on the new flywheel.

Note. Special bolts are used for installation. Do not use standard bolts.

1. Inspect the pilot bearing. Install a new pilot bearing as necessary.
2. Install the flywheel and the 6 bolts.
3. Install the special tool.
4. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
5. Install the clutch and manual transaxle. For additional information, refer to «CLUTCH»(ref-278299) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-278298) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the flywheel or flexplate. For additional information, refer to «Flywheel»(ref-278254-S09803544662008012400000) or «Flexplate»(ref-278254-S26261915952008012400000) .
3. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
4. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
5. Remove the 17 bolts and the oil pan.
6. Remove the 6 bolts and the crankshaft rear seal with retainer plate.

1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear seal with retainer plate and 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan, cylinder block and front cover flange mating surfaces.
4. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan and the 2 bolts finger-tight.
5. Install the 4 front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
7. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
8. Install the flywheel or flexplate. For additional information, refer to «Flywheel»(ref-278254-S09803544662008012400000) or «Flexplate»(ref-278254-S26261915952008012400000) .
9. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
3. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-278254-S40379588202008012400000) .
4. Remove the engine mount. For additional information, refer to «Engine Mount»(ref-278254-S03634692352008012400000) .
5. If equipped, detach the 2 wiring harness retainers from the power steering reservoir.
6. Disconnect the power steering pressure (PSP) switch electrical connector.
7. Using the special tool, remove the power steering pump pulley.
8. Remove the PSP tube bracket nut.
9. Disconnect the PSP tube from the power steering pump. Remove and discard the Teflon® O-ring seal.
10. Remove the 4 power steering pump mounting bolts and position the power steering pump aside.
11. Using the special tool, remove the crankshaft front oil seal.
12. Remove the 3 bolts and the coolant pump pulley.
13. Disconnect the crankshaft position (CKP) sensor electrical connector. Detach the 2 wiring harness retainers from the engine front cover.
14. Remove and discard the CKP sensor.
15. Remove the bolts and the engine front cover.

1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 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. Install the coolant pump pulley and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
5. Using the special tool, install the crankshaft front oil seal.
6. Install the engine mount. For additional information, refer to «Engine Mount»(ref-278254-S03634692352008012400000) .
7. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-278254-S40379588202008012400000) .
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. Adjust the new CKP sensor with the alignment jig. Tighten the 2 bolts to 7 Nm (62 lb-in).
11. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers to the engine front cover.
12. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
13. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
14. Using the special tool, install a new Teflon® O-ring seal to the PSP tube.
15. Install the PSP tube onto the power steering pump. Tighten to 65 Nm (48 lb-ft).
16. Install the PSP tube bracket nut. Tighten to 11 Nm (8 lb-ft).
17. Using the special tool, install the power steering pump pulley.
18. Connect the PSP switch electrical connector.
19. If equipped, attach the 2 wiring harness retainers to the power steering reservoir.
20. Install the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
21. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-278262) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-278254-S39824775732008012400000) .
3. Remove the timing chain tensioner. Compress the timing chain tensioner and insert a paper clip into the hole. Remove the bolts and timing chain tensioner.
4. Remove the RH timing chain guide.
5. Remove the timing chain.
6. Remove the bolts and the LH timing chain guide.
7. Remove the bolts and the camshaft drive gears. Use the flats on the camshaft to prevent camshaft rotation.

1. Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and bolts. Tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the RH timing chain guide.
5. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gears bolts. Tighten to 72 Nm (53 lb-ft).
7. Install the front cover. For additional information, refer to «Engine Front Cover»(ref-278254-S39824775732008012400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
3. Remove the RF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-278246) article.
4. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-278254-S38474388132008012400000) .
5. Remove the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
6. 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.
7. Install the special tool in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. Install the special tool.
10. 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.
11. Remove the front cover lower timing hole plug from the engine front cover.
12. Remove the front cover upper timing hole plug from the engine front cover.
13. Reposition the special tool to the slot on the rear of the intake camshaft only.
14. 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 place.
15. Remove the special tool.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
17. Remove the timing chain from the intake camshaft drive gear.
18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.

1. 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 (12 lb-ft).
2. Install the special tool.
3. Install the intake camshaft drive gear and hand-tighten the bolt.
4. Install the timing chain on the intake camshaft drive gear.
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 unlock the tensioner arm.
7. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts. Tighten to 72 Nm (53 lb-ft).
8. Remove the special tool.
9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
10. Remove the special tool.
11. Install the front cover upper timing hole plug. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the front cover lower timing hole plug. Install the plug and tighten to 12 Nm (9 lb-ft).
13. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
14. Install the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
15. Install the RF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-278246) article.
16. Install the valve cover. For additional information, refer to «Valve Cover»(ref-278254-S19664308962008012400000) .
17. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-278250) article.

Scheme 5

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-278254-S15427438962008012400000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L AND 2.3L»(ref-278300) article.
5. Connect the compressed air supply to cylinder No. 1.
6. Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
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 - 2.0L AND 2.3L»(ref-278300) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «Camshafts»(ref-278254-S15427438962008012400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-278254-S15427438962008012400000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L AND 2.3L»(ref-278300) article.
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 special tools, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the special tools, remove and discard the valve seal.

1. Install the valve stem seal installation sleeve.
2. Using the special tool, install the valve seal.
3. Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L AND 2.3L»(ref-278300) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «Camshafts»(ref-278254-S15427438962008012400000) .

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-278254-S15427438962008012400000) .
3. Remove and inspect the valve tappets. For additional information refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

All engines

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
3. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
4. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-278254-S38474388132008012400000) .
5. Remove the nuts and disconnect the catalytic converter from the exhaust assembly. Remove and discard the gasket.
6. Remove the 2 bolts and the catalytic converter support bracket from the engine.
7. If equipped, remove the 4 heat shield bolts and position the heat shield aside.
8. Disconnect the exhaust sensor electrical connectors.
9. Remove and discard the catalytic converter-to-engine nuts. Position aside the catalytic converter and support with mechanic's wire. Remove and discard the catalytic converter gasket.
10. Remove the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-278251) article.
11. Remove the fuel injection supply manifold. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L AND 2.3L»(ref-278259) article.
12. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-278254-S23399251862008012400000) .
13. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(ref-278254-S35485438552008012400000) .
14. Remove the special tool.
15. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
16. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.
17. Remove the valve tappets.
18. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.
19. If equipped, disconnect the secondary air injection (AIR) vacuum regulator electrical connector and vacuum hose.
20. If equipped, disconnect the hoses from the AIR control valve.
21. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
22. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
23. Disconnect the coolant hoses from the coolant bypass.
24. Remove the 4 bolts, coolant bypass and gasket. Discard the gasket.
25. Disconnect the EGR coolant hose.
26. Remove the bolts and the cylinder head. Discard the bolts.
27. Remove and discard the head gasket.
28. Inspect the cylinder head mating surfaces. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.

All engines

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256) article.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new head gasket.
6. 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 (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Install the EGR coolant hose.
8. Using a new gasket, install the coolant bypass and the 4 bolts. Tighten to 10 Nm (89 lb-in).
9. Connect the coolant hoses onto the coolant bypass.
10. Connect the EGR valve electrical connector.
11. Clean and inspect the catalytic converter flange. Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
12. Using a new gasket and 7 nuts, install the catalytic converter. Tighten to 55 Nm (41 lb-ft).
13. Connect the exhaust sensor electrical connectors.
14. If equipped, position the heat shield and install the 4 heat shield bolts. Tighten to 11 Nm (8 lb-ft).
15. Install the catalytic converter support bracket and the 2 bolts to the engine. Tighten to 47 Nm (35 lb-ft).
16. If equipped, connect the upper exhaust sensor electrical connector and retainer.
17. If equipped, connect the hoses to the AIR control valve.
18. If equipped, connect the AIR vacuum regulator electrical connector and vacuum hose.
19. Install the valve tappets in their original positions.
20. 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 the cam is fully seated. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
21. Install the timing drive components. For additional information, refer to «Timing Drive Components»(ref-278254-S35485438552008012400000) .
22. Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-278254-S23399251862008012400000) .
23. Install the fuel injector supply manifold. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L AND 2.3L»(ref-278259) article.
24. Install the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-278251) article.
25. Connect the radio interference capacitor electrical connector.
26. Install the dual cooling fans and connect the electrical connectors.
27. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
28. Drain the engine oil and change the filter. Tighten the plug to 28 Nm (21 lb-ft).
29. Fill the engine with clean engine oil.
30. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
31. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-278262) article.

Scheme 6

Note. Automatic transmission shown, manual transmission similar.

Scheme 7

Scheme 8

Scheme 9

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Disconnect the engine oil pressure (EOP) switch electrical connector.
3. Remove the EOP switch.
4. Remove and discard the oil filter.
5. Remove the 4 bolts and the oil filter adapter. Discard the gasket.

1. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
2. Install a new oil filter. Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
3. Install the EOP switch. Tighten to 15 Nm (11 lb-ft).
4. Connect the EOP switch electrical connector.
5. Top off the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Disconnect the engine oil pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 15 Nm (11 lb-ft).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
3. Detach the 2 positive battery cable pin-type retainers and position aside.
4. Detach the transmission connector wire harness pin-type retainer and position aside.
5. Remove the 2 nuts and position the heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket aside.
6. Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in).
7. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
8. Loosen the 3 (manual transmission) or 2 (automatic transmission) front lower bellhousing-to-engine bolts 5 mm (0.19 in).
9. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
10. Remove the 2 bellhousing-to-oil pan bolts.
11. Remove the 2 oil pan-to-bellhousing bolts.
12. Slide the transmission rearward 5 mm (0.19 in).
13. Remove the 2 bolts and the accessory drive belt splash shield.
14. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
15. Remove the 4 engine front cover-to-oil pan bolts.
16. Remove the 13 bolts and the oil pan.

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-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
6. Install the accessory drive belt splash shield and the 2 bolts. Tighten to 9 Nm (80 lb-in).
7. Alternate tightening the 1 front bellhousing-to-engine and 1 rear engine-to-bellhousing lower bolts to slide the transmission and engine together. Tighten to 48 Nm (35 lb-ft).
8. Tighten the remaining 1 (automatic transmission) or 2 (manual transmission) lower front bellhousing-to-engine bolt(s) and the remaining rear engine-to-bellhousing stud bolt. Tighten to 48 Nm (35 lb-ft).
9. Install the 2 bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
10. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
11. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
12. Tighten the top bellhousing-to-engine bolt and stud bolt. Tighten to 48 Nm (35 lb-ft).
13. Position the HO2S and catalyst monitor sensor wire connector bracket and install the 2 nuts. Tighten to 25 Nm (18 lb-ft).
14. Position and attach the transmission connector wire harness pin-type retainer.
15. Position and attach the 2 positive battery cable pin-type retainers.
16. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
17. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-278254-S22979024862008012400000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the gasket.

1. Clean and inspect all mating surfaces.
2. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «Oil Pan»(ref-278254-S22979024862008012400000) .

Note. Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

All vehicles

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-278254-S39824775732008012400000) .
3. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
4. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
5. Remove the 4 oil pan-to-bellhousing bolts.
6. Remove the 13 bolts and the oil pan.
7. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
8. Remove the oil pump drive chain tensioner and guide. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner. Remove the 2 shoulder bolts and the guide.
9. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
10. Remove the chain from the oil pump sprocket.
11. Remove the bolt and oil pump sprocket.
12. Remove the 4 bolts and the oil pump.

All vehicles

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 (15 lb-ft).
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 guide and the shoulder bolts. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
7. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Clean all mating surfaces with metal surface cleaner.
9. 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.
10. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
11. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-278254-S04886552882008012400000) .
14. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-278254-S39824775732008012400000) .
15. Fill the engine with clean engine oil.

1. Remove the oil level indicator and position aside.
2. Remove the 2 bolts for 2.3L engines or the 1 bolt for 2.0L engines and the oil level indicator tube. To install, tighten to 10 Nm (89 lb-in).
3. To install, reverse the removal procedure.

1. Remove the expansion tank bolt. To install, tighten to 10 Nm (89 lb-in).
2. Lift the coolant expansion tank out of the retainer and position it aside.
3. Install the special tool.
4. Remove the 2 engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
5. Remove the 3 bolts and the engine mount. To install, tighten to 48 Nm (35 lb-ft).
6. To install, reverse the removal procedure.

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift with Tilting Plate 014-00765 or equivalent Universal Adapter Brackets 014-0001 Torque Converter Holding Tool 307-346 (T97T-7902-A) Lifting Bracket, Engine 303-050 (T70P-6000) Tie-Rod End Remover 211-001 (TOOL-3290-D) or equivalent Transaxle Plugs 308-152 (T88C-7025-AH) Slide Hammer 100-001 (T50T-100-A) Front Drive Halfshaft Remover 205-241 (T86P-3514-A)

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
4. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
5. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-278244) article.
6. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-278284) article.
7. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
8. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
9. Remove the 2 nuts and disconnect the catalytic converter from the muffler assembly. Remove and discard the gasket.
10. Remove the 4 bolts and the catalytic converter support bracket.
11. If equipped, remove the 4 heat shield bolts and position the heat shield aside.
12. Disconnect the exhaust sensor electrical connectors.
13. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
14. If equipped, disconnect the secondary air injection (AIR) hose.
15. Remove and discard the 7 catalytic converter-to-engine nuts. Position aside the catalytic converter and support with mechanic's wire. Remove and discard the catalytic converter gasket.
16. Loosen the clamp and disconnect the vent tube from the air cleaner outlet pipe.
17. Remove the 2 bolts and detach the air intake resonator from the grommets. Remove the air intake resonator and outlet pipe.
18. Remove the accelerator control snow shield. Detach the evaporative emissions (EVAP) hose pin-type retainer. Remove the screw, the pin-type retainer and the snow shield.
19. Disconnect the accelerator cable and speed control cable (if equipped). Disconnect the accelerator and speed control cable (if equipped) from the throttle body. Remove the 3 bolts and position the accelerator control cables and bracket aside.
20. Disconnect the fuel tube quick connect coupling from the fuel rail and position the fuel tube aside. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
21. Disconnect the evaporative emissions tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
22. If equipped, disconnect the AIR hose.
23. If equipped, disconnect the AIR vacuum regulator electrical connector.
24. Disconnect the power brake booster vacuum tube. Depress the quick connect locking ring. Pull the vacuum tube out of the quick connect fitting.
25. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
26. Disconnect the upper radiator hose, the heater hose and the coolant vent hose from the coolant bypass.
27. Remove the bolt and ground eyelet.
28. Disconnect the fuel charging wiring harness electrical connector and harness retainer.
29. Disconnect the fuel charging wiring harness electrical connector.
30. Disconnect the power distribution wiring harness electrical connector.
31. Detach the wiring harness retainers.
32. Remove the nut and the power distribution wiring harness eyelet.
33. Disconnect the 3 main engine wiring harness electrical connectors and detach the connectors from the bracket.
34. Detach the gearshift cables from the transaxle. Detach the shifter cable from the shift mass. Detach the selector cable from the selector lever.
35. Detach the gearshift cables from the bracket. Detach the shifter cable from the retaining bracket, turning the abutment sleeves counterclockwise. Detach the selector cable from the retaining bracket, turning the abutment sleeves counterclockwise.
36. Remove the clutch slave cylinder supply tube. Remove the clip. Remove the supply tube and secure it to one side using cable ties.
37. Disconnect the reversing lamp switch electrical connector.
38. Disconnect the transmission shifter cable and position it aside.
39. Disconnect the transmission cooler hoses.
40. Disconnect the heater hose from the "T" fitting and position it aside.
41. Disconnect the coolant hoses from the coolant expansion tank.
42. Remove the coolant expansion tank bolt.
43. Remove the coolant expansion tank. Lift the coolant expansion tank out of the retainer.
44. Disconnect the cooling fan electrical connectors.
45. Release the top cooling fan retaining clips, lift up and remove the cooling fan.
46. Disconnect the lower radiator hose.
47. Remove the bolt and the ground cable.
48. Remove the generator cooling pipe.
49. Disconnect the starter motor electrical terminals.
50. Remove the 2 nuts and detach the PSP tube brackets from the stud bolts.
51. Disconnect the A/C compressor electrical connector.
52. Remove the 3 A/C compressor bolts.
53. Loosen the bolt and remove the A/C compressor. Lower the A/C compressor to access the manifold bolt. Discard the O-ring seals.
54. Detach the LH brake hose from the support bracket.
55. Detach the LH caliper. Remove the bolt covers. Remove the 2 bolts.
56. Support the brake caliper.
57. Loosen the LH strut and spring assembly top mount nuts by 4 turns.
58. Remove the nut and disconnect the LH stabilizer bar at the strut.
59. Remove the LH tie-rod end nut.
60. Remove the RH tie-rod end nut.
61. Using the special tool, disconnect both tie rods from the knuckles.
62. Remove the bolts and disconnect both lower control arms from the knuckles.
63. Remove the 2 nuts and the intermediate shaft bearing bracket.
64. Remove the intermediate shaft and RH front drive halfshaft assembly from the transaxle. Position it aside and support with mechanic's wire. Install a plug into the transaxle opening.
65. Using the special tools, remove the LH front drive halfshaft from the transaxle. Position it aside and support with mechanic's wire. Install a plug into the transaxle opening.
66. Remove the 2 bolts and the transaxle roll restrictor.
67. Remove the 3 bolts and the starter.
68. Remove the starter isolator.
69. Remove the 2 lower bellhousing bolts.
70. Remove the 2 oil pan-to-bellhousing bolts.
71. Using the special tools, fasten the engine to the lift table.
72. Remove the 2 engine mount nuts.
73. Remove the transaxle mount center nut.
74. Lower the engine and transaxle assembly from the vehicle.
75. Disconnect the vehicle speed sensor (VSS) electrical connector.
76. Remove the 4 torque converter nuts.
77. Disconnect the output shaft speed (OSS) sensor electrical connector.
78. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
79. Disconnect the solenoid body and the transmission range (TR) sensor electrical connectors.
80. Using the engine crane, remove the engine and transaxle assembly from the lift table.
81. Remove the remaining bellhousing bolts and separate the engine and transmission.
82. Remove and discard the dowel pins.
83. Install the special tool, to prevent damage to the torque converter.

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Locking Tool, Flywheel 303-103 (T74P-8375-A) Engine Stand 014-00232 or equivalent Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-507 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02) Remover, Oil Seal 303-409 (T92C-6700-CH)

Note. For additional information, refer to the exploded view under the assembly procedure in this article.

Note. Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

Vehicles equipped with a manual transmission

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. Remove the 7 bolts, clutch pressure plate and clutch disc.
2. Install the special tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
5. Remove the 3 nuts and the generator heat shield.
6. Remove the nut and disconnect the generator electrical connections and wiring harness retainer.
7. Remove the nut and the wiring harness retainer.
8. Remove the bolt, the 2 stud bolts and the generator.
9. Remove the 2 bolts and the accessory drive belt tensioner.
10. Loosen the bolt and remove the accessory drivebelt idler pulley.
11. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
12. Remove the 3 bolts and the coolant pump pulley.
13. Remove the 3 bolts and the coolant pump.
14. Disconnect the heater hose from the thermostat housing.
15. Remove the 3 bolts and the thermostat housing.
16. Disconnect the oil pressure sensor electrical connector.
17. Remove the engine oil filter.
18. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
19. Disconnect the knock sensor (KS) electrical connector and pin-type retainer.
20. Remove the lower intake manifold bolt.
21. Disconnect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
22. Disconnect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
23. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
24. Detach the wiring harness pin-type retainer.
25. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
26. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
27. If equipped, disconnect the secondary air injection (AIR) vacuum supply hose.
28. Disconnect the swirl control valve electrical connector.
29. Remove the bolt and the oil level indicator tube.
30. Remove the 7 intake manifold bolts.
31. Disconnect the swirl valve electrical connectors and pin-type retainers.
32. Remove the 2 bolts and the oil level indicator and tube.
33. Remove the 7 intake manifold bolts.
34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
35. Remove the exhaust gas recirculation (EGR) tube.
36. Remove the radio interference capacitor bracket bolt and position the bracket aside.
37. Disconnect the wiring harness retainers from the valve cover studs and position aside.
38. Disconnect the fuel charging wiring harness. Disconnect the fuel rail pressure and temperature sensor electrical connector. Disconnect the 4 fuel injector electrical connectors. Detach the wiring harness retainers.
39. Remove the 2 bolts and the fuel rail with the fuel injectors.
40. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
41. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
42. Disconnect and remove the coolant hose.
43. Disconnect the coolant bypass hose.
44. Remove the 4 bolts and the coolant bypass.
45. Disconnect and remove the coolant bypass hose.
46. Remove the bolt and the KS.
47. Remove the 8 bolts and the crankcase vent oil separator.
48. If equipped, remove the block heater.
49. Remove the crankcase vent tube and the coil-on-plugs.
50. Remove the spark plugs and the CHT sensor. Discard the CHT.
51. Remove the bolts and the valve cover.
52. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
53. Install the special tool in the slots on the rear of both camshafts.
54. Remove the engine plug bolt.
55. Install the special tool.
56. Assemble the special tools using 4 hardened washers in the locations shown.
57. Using the special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
58. Using the special tool, remove the crankshaft front oil seal.
59. Remove and discard the CKP sensor.
60. Remove the 22 bolts and the engine front cover.
61. Remove the timing chain tensioner. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner. Remove the 2 bolts and timing chain tensioner.
62. Remove the RH timing chain guide.
63. Remove the timing chain.
64. Remove the 2 bolts and the LH timing chain guide.
65. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
66. Remove the oil pump drive chain tensioner and guide. Release the tension on the tensioner spring. Remove the tensioner and the shoulder bolt. Remove the guide.
67. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
68. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
70. 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.
71. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
72. Remove the cylinder head alignment dowels.
73. Remove the 13 bolts and the oil pan.
74. Remove the 6 bolts and the rear crankshaft seal.
75. Remove the 2 bolts, oil pump pickup tube and gasket.
76. Remove the 4 bolts and the oil pump.
77. Remove the 3 bolts and the intermediate shaft bearing bracket.
78. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center (TDC). Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. see scheme 354: Installing Crankshaft TDC Timing Peg
79. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. see scheme 355: Locating Balancer Unit And Shafts Reference Mark
80. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. see scheme 356: Locating Balancer Unit Bolts
81. Remove the Crankshaft TDC Timing Peg. see scheme 357: Installing Crankshaft TDC Timing Peg
82. 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.
83. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly. Remove the connecting rod cap bolts and cap. see scheme 358: Locating Connecting Rod Cap Bolts
84. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. 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. see scheme 359: Identifying Connecting Rod Installer
85. Remove the bolts in the sequence shown. Remove the main bearing beam. Discard the bolts. see scheme 360: Identifying Crankshaft Cap Bolts Removing Sequence
86. Remove the crankshaft from the engine block. see scheme 361: Locating Crankshaft
87. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. Remove the main bearings from the main bearing beam. see scheme 362: Locating Main Bearings
88. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing. Remove the main bearings from the cylinder block. see scheme 363: Locating Main Bearings
89. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter. Remove the 4 oil squirters. see scheme 364: Locating Oil Squirters
90. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-278256).