Engine Mechanical - 2.0L: Removal & Installation Ford Focus II facelift

REMOVAL

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
3. Remove the front impact severity sensor. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.
4. Remove the transaxle fluid indicator.
5. Remove the lower intake manifold bolt.
6. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-357159-S35025346082010030800000) .
7. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire harness retainer from the starter stud bolt.
8. Disconnect the electronic throttle control electrical connector.
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 Manifold Absolute Pressure (MAP) sensor electrical connector.
12. Detach and disconnect the Knock Sensor (KS) electrical connector.
13. If equipped, disconnect the swirl control valve solenoid electrical connector.
14. If equipped, disconnect the swirl control valve sensor electrical connector.
15. Detach all the wiring harness pin-type retainers from the intake manifold.
16. Loosen the 2 intake manifold bolts.
17. Remove the 5 intake manifold bolts.
18. Disconnect the PCV hose and remove the intake manifold.

INSTALLATION

1. Inspect and install new intake manifold gaskets if necessary.
2. Position the intake manifold and connect the PCV hose.
3. Attach the KS to the intake manifold and connect the KS electrical connector.
4. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
5. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 Nm (159 lb-in).
6. Attach all the wiring harness pin-type retainers to the intake manifold.
7. If equipped, connect the swirl control valve sensor electrical connector.
8. If equipped, connect the swirl control valve solenoid electrical connector.
9. Connect the MAP sensor electrical connector.
10. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting.
11. Connect the fuel vapor return hose.
12. Connect the electronic throttle control electrical connector.
13. Connect the EOP switch electrical connector and attach the wire harness retainer to the starter stud bolt.
14. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-357159-S35025346082010030800000) .
15. Install the lower intake manifold bolt. Tighten to 18 Nm (159 lb-in).
16. Install the transaxle fluid indicator.
17. Install the front impact severity sensor. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.
18. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.

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. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Disconnect the 4 ignition coil-on-plug electrical connectors.
3. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
4. Lift up the connector boot and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
5. Disconnect the crankcase breather tube from the valve cover.
6. Detach all of the wiring harness retainers from the valve cover stud bolts.
7. Disconnect the generator B+ wire harness retainer from the valve cover stud bolt.
8. Disconnect the generator electrical connector.
9. Remove the radio interference capacitor bracket bolt.
10. Remove the radio interference capacitor ground bolt and position the bracket aside.
11. Remove the 14 valve cover retainers, the valve cover and gasket. Discard the valve cover gasket.

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown in illustration.
3. Install the valve cover, a new gasket and the 14 retainers. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
4. Position the radio interference capacitor bracket and install the bolt. Tighten to 10 Nm (89 lb-in).
5. Install the radio interference capacitor ground bolt. Tighten to 10 Nm (89 lb-in).
6. Connect the generator electrical connector.
7. Connect the generator B+ wire harness retainer to the valve cover stud bolt.
8. Attach all of the wiring harness retainers to the valve cover stud bolts.
9. Connect the crankcase breather tube on the valve cover.
10. Connect the CHT sensor electrical connector and install the connector boot.
11. Install the ignition coils and the 4 ignition coil-to-valve cover bolts. Tighten to 10 Nm (89 lb-in).
12. Connect the 4 ignition coil-on-plug electrical connectors.
13. Connect the CMP sensor electrical connector.

Scheme 8

Scheme 9

1. For additional information, refer to the appropriate procedures in this service information.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
4. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-357159-S04374960302010030800000) .
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. Assemble the Drive Pinion Flange Holding Fixture and Adapter using 4 hardened washers in the locations shown in illustration.
10. Using the Adapter and Drive Pinion Flange Holding Fixture 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 x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. Assemble the Drive Pinion Flange Holding Fixture and Adapter using 4 hardened washers in the locations shown in illustration.
5. Install a new crankshaft pulley bolt. Using the Drive Pinion Flange Holding Fixture and Adapter 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 (one-fourth turn).
6. Remove the 6 mm x 18 mm bolt.
7. Remove the Crankshaft TDC Timing Peg.
8. Remove the Camshaft Alignment Plate.
9. Turn the crankshaft clockwise one and three-fourths turns.
10. Install the Crankshaft TDC Timing Peg.
11. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
12. 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.
13. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
14. Remove the Camshaft Alignment Plate.
15. Remove the 6 mm x 18 mm bolt.
16. Remove the Crankshaft TDC Timing Peg.
17. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
18. Install the valve cover. For additional information, refer to «Valve Cover»(ref-357159-S04374960302010030800000) .
19. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
20. Install the RF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.

1. Remove the crankshaft pulley. For additional information, refer to «Lower End Components»(ref-357159-S04961135262010030800000) and «Crankshaft Pulley»(ref-357159-S40937782842010030800000) .
2. Using the Oil Seal Remover, remove the crankshaft front oil seal.

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»(ref-357159-S04961135262010030800000) and «Crankshaft Pulley»(ref-357159-S40937782842010030800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E»(ref-357160) article.
3. Install the Flywheel Holding Tool and remove the 6 flexplate bolts and the flexplate.

1. Install the flexplate.
2. Install the Flywheel Holding Tool.
3. Tighten the bolts in the sequence shown in illustration 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 - 4F27E»(ref-357160) article.

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-357166) article and «MANUAL TRANSAXLE/TRANSMISSION - MTX75»(ref-357161) article.
3. Install the Flywheel Holding 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 Flywheel Holding Tool.
4. Tighten the bolts in the sequence shown in illustration 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-357166) article and «MANUAL TRANSAXLE/TRANSMISSION - MTX75»(ref-357161) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the flywheel or flexplate. For additional information, refer to «Flywheel»(ref-357159-S39810401222010030800000) or «Flexplate»(ref-357159-S01690282732010030800000) .
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-357159-S35025346082010030800000) .
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 Crankshaft Rear Main Oil Seal Installer, 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 in illustration 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 in illustration 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-357159-S35025346082010030800000) .
8. Install the flywheel or flexplate. For additional information, refer to «Flywheel»(ref-357159-S39810401222010030800000) or «Flexplate»(ref-357159-S01690282732010030800000) .
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-357126) article.
2. Depower the Supplemental Restraint System (SRS). For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.
3. Loosen the 3 coolant pump pulley bolts.
4. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-357159-S40937782842010030800000) .
5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Detach the 2 wiring harness retainers from the engine front cover.
6. Remove the 2 bolts and the CKP sensor.
7. Using the Oil Seal Remover, remove the crankshaft front oil seal.
8. Remove the 3 bolts and the coolant pump pulley.
9. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
10. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
11. Remove the engine mount. For additional information, refer to «Engine Mount»(ref-357159-S02439997222010030800000) .
12. Slightly raise the engine for access to the accessory drive idler pulley.
13. Remove the accessory drive idler pulley. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
14. 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 in illustration, 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 accessory drive idler pulley. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
5. Lower the engine to the installed position.
6. Install the engine mount. For additional information, refer to «Engine Mount»(ref-357159-S02439997222010030800000) .
7. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
8. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
9. Install the coolant pump pulley and the 3 bolts. Do not tighten at this time.
10. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
11. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-357159-S40937782842010030800000) .
12. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
13. Install the CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
14. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 bolts to 7 Nm (62 lb-in).
15. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers to the engine front cover.
16. Remove the 6 mm x 18 mm bolt.
17. Tighten the coolant pump pulley bolts. Tighten to 20 Nm (177 lb-in).
18. Repower the SRS. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.
19. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-357137) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-357159-S17473324612010030800000) .
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 gear bolts. Tighten to 72 Nm (53 lb-ft).
7. Install the front cover. For additional information, refer to «Engine Front Cover»(ref-357159-S17473324612010030800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
3. Remove the RF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
4. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-357159-S07668297582010030800000) .
5. Remove the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) 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 Camshaft Alignment Plate in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. Install the Crankshaft TDC Timing Peg.
10. Install a standard 6 mm x 18 mm 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 Camshaft Alignment Plate 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 bolt into the upper front cover timing hole to hold the tensioner arm in place.
15. Remove the Camshaft Alignment Plate.
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 illustration 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).
2. Install the Camshaft Alignment Plate.
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 Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
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 (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»(ref-357139) article.
15. Install the RF wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
16. Install the valve cover. For additional information, refer to «Valve Cover»(ref-357159-S04374960302010030800000) .
17. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-357157) article.

Scheme 10

1. For additional information, refer to the procedures in this service information.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-357159-S13146139022010030800000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-357158) 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 Valve Spring Compressors, 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 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 - 2.0L»(ref-357158) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «Camshafts»(ref-357159-S13146139022010030800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-357159-S13146139022010030800000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-357158) 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 Valve Spring Compressors, 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.
7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.

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 multi-purpose 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»(ref-357158) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «Camshafts»(ref-357159-S13146139022010030800000) .

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-357159-S13146139022010030800000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
2. Depower the Supplemental Restraint System (SRS). For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
5. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-357159-S07668297582010030800000) .
6. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
7. Remove the 2 nuts and disconnect the flex pipe from the muffler and tailpipe assembly. Remove and discard the nuts and gasket.
8. Remove the 2 bolts from the catalytic converter-to-engine support bracket.
9. Remove the 2 bolts and the catalytic converter support bracket.
10. Remove the 6 bolts and the catalytic converter heat shield.
11. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors.
12. Remove and discard the catalytic converter nuts. Position aside the catalytic converter and support with mechanic's wire. Remove and discard the catalytic converter gasket.
13. Remove the engine oil filter and discard.
14. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L»(ref-357163) article.
15. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-357159-S41551136572010030800000) .
16. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(ref-357159-S29578189132010030800000) .
17. Remove the Camshaft Alignment Plate.
18. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
19. 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.
20. Remove the valve tappets.
21. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
22. Remove the 3 bolts and position the wiring harness and bracket aside.
23. Disconnect the EGR valve electrical connector.
24. Disconnect the coolant hoses from the coolant bypass.
25. Disconnect the EGR coolant hose.
26. Remove the 7 catalytic converter-to-cylinder head studs and discard.
27. Lower the engine and remove the Engine Support Bar.
28. Remove the 10 bolts and the cylinder head. Discard the bolts.
29. Remove and discard the head gasket.
30. Inspect the cylinder head mating surfaces. For additional information, Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.

Scheme 11

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. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. 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-357133) article.
4. Apply silicone gasket and sealant to the locations shown in illustration.
5. Install a new cylinder head gasket.
6. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Install the Engine Support Bar and raise the engine.
8. Install the 7 new catalytic converter-to-cylinder head studs. Tighten to 17 Nm (150 lb-in).
9. Install the EGR coolant hose.
10. Connect the coolant hoses onto the coolant bypass.
11. Connect the EGR valve electrical connector.
12. Position the wire harness bracket and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
13. Install the valve tappets in their original positions.
14. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration 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 to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
15. Install the timing drive components. For additional information, refer to «Timing Drive Components»(ref-357159-S29578189132010030800000) .
16. Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-357159-S41551136572010030800000) .
17. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L»(ref-357163) article.
18. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust manifold cleaning and inspection in «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article. Using a straightedge and 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.
19. Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 55 Nm (41 lb-ft). Stage 2: Tighten to 55 Nm (41 lb-ft).
20. Connect the HO2S and CMS electrical connectors.
21. Install the catalytic converter heat shield and 6 bolts. Tighten to 11 Nm (97 lb-in).
22. Install the catalytic converter support bracket and the 2 bolts. Tighten to 22 Nm (16 lb-ft).
23. Install the 2 catalytic converter-to-engine support bracket bolts. Tighten to 48 Nm (35 lb-ft).
24. Using a new gasket and 2 new nuts, connect the muffler and tailpipe assembly to the flexpipe. Tighten to 48 Nm (35 lb-ft).
25. Install the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
26. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
27. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
28. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
29. Fill the engine with clean engine oil.
30. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
31. Repower the SRS. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-357180) article.

Scheme 12

Note. Automatic transaxle shown in illustration, manual transaxle similar.

Scheme 13

Note. Automatic transaxle shown in illustration in illustration, manual transaxle similar.

Scheme 14

Scheme 15

1. For additional information, refer to the appropriate procedures in this service information.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) 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 three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
3. Install the EOP switch. Tighten to 15 Nm (133 lb-in).
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-357126) article.
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
3. Remove the 2 nuts and position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket aside.
4. Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in).
5. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-357159-S35025346082010030800000) .
6. Loosen the 3 (manual transaxle) or 2 (automatic transaxle) LH bellhousing-to-engine bolts 5 mm (0.19 in).
7. Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
8. Remove the 2 bellhousing-to-oil pan bolts.
9. Remove the 2 oil pan-to-bellhousing bolts.
10. Slide the transaxle rearward 5 mm (0.19 in).
11. Remove the 2 bolts and the accessory drive belt splash shield.
12. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
13. Remove the 4 engine front cover-to-oil pan bolts.
14. 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 13 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 in illustration. 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 LH bellhousing-to-engine and 1 RH engine-to-bellhousing lower bolts to slide the transaxle and engine together. Tighten to 48 Nm (35 lb-ft).
8. Tighten the remaining 1 (automatic transaxle) or 2 (manual transaxle) LH 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 bolts. 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-357159-S35025346082010030800000) .
12. Tighten the top bellhousing-to-engine bolt and stud bolt. Tighten to 48 Nm (35 lb-ft).
13. Position the HO2S and CMS wire connector bracket and install the 2 nuts. Tighten to 25 Nm (18 lb-ft).
14. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
15. 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-357126) article.
2. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-357159-S40337971382010030800000) .
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-357159-S40337971382010030800000) .

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-357159-S17473324612010030800000) .
3. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-357159-S35025346082010030800000) .
4. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
5. Remove the 2 oil pan-to-bellhousing bolts.
6. Remove the 2 bellhousing-to-oil pan bolts.
7. Remove the 13 bolts and the oil pan.
8. Remove the 2 bolts and the oil pump screen and pickup tube.
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.

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Clean all mating surfaces with metal surface prep.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
11. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 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-357159-S35025346082010030800000) .
14. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-357159-S17473324612010030800000) .
15. Fill the engine with clean engine oil.

1. Remove the oil level indicator and position aside.
2. Remove the oil level indicator tube bolt. To install, tighten to 10 Nm (89 lb-in).
3. Remove the oil level indicator tube and discard the O-ring seal. To install, lubricate the new O-ring seal with clean engine oil.
4. To install, reverse the removal procedure.

1. Remove the 2 expansion tank bolts. To install, tighten to 4 Nm (35 lb-in).
2. Lift the coolant expansion tank off of the engine mount stud bolt and position it aside.
3. Install the Engine Support Bar.
4. Remove the 2 engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
5. Remove the 2 bolts, stud bolt and the engine mount. To install, tighten to 48 Nm (35 lb-ft).
6. To install, reverse the removal procedure.

Engine - Automatic Transaxle

SPECIAL TOOLS Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Retainer, Torque Converter 307-346 (T97T-7902-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-357136) article.
4. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
5. Disconnect the crankcase vent tube from the valve cover.
6. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
7. Disconnect the positive battery cable nut.
8. Detach the 2 positive battery cable wire harness retainers.
9. Remove the bolt and the negative battery cable ground.
10. Disconnect the fuel tube quick connect coupling from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
11. Disconnect the Evaporative Emission (EVAP) and position aside. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
12. Disconnect the power brake booster vacuum tube. Depress the quick connect locking ring. Pull the vacuum tube out of the quick connect fitting.
13. Detach the brake booster vacuum hose retainer.
14. Detach and disconnect the 2 engine harness electrical connectors.
15. Detach the engine harness from the coolant outlet bracket harness retainer.
16. Disconnect the 3 PCM electrical connectors.
17. Disconnect the starter wire harness electrical connector.
18. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and detach the wire harness retainer.
19. Disconnect the transaxle shift cable from the lever and bracket.
20. Remove the transmission fluid cooler tube secondary latches.
21. Disconnect the 2 transaxle fluid cooler tubes from the transaxle. Squeeze the tabs together. Slide the transaxle fluid cooler tube lock up and remove the transaxle fluid cooler tubes from the transaxle.
22. Disconnect the 2 transaxle electrical connectors.
23. Detach the shift cable from the retainer.
24. Remove the engine oil level indicator.
25. Remove the bolt and the radio capacitor ground cable.
26. Remove the 2 front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
27. Remove the retainers and the splash shield.
28. Remove the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
29. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
30. Detach the 4 B+ battery cable wire harness retainers (2 shown in illustration) and position aside.
31. Remove the 2 A/C tube nuts.
32. Remove the nut and the A/C tube bracket from the A/C compressor stud bolt.
33. Disconnect the A/C tubes from the compressor. Discard the 2 O-ring seals.
34. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
35. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
36. Disconnect the lower radiator hose from the radiator.
37. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
38. Remove the engine oil filter and discard.
39. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-357140) article.
40. Remove the bolt and the power steering tube clip.
41. Remove the bolt and the power steering tubes from the steering gear. Discard the 2 power steering tube O-ring seals.
42. Remove the 2 nuts and disconnect the flexpipe from the muffler and tailpipe assembly. Remove and discard the nuts and gasket.
43. Remove the 2 catalytic converter support bracket-to-engine bolts.
44. Remove the 2 bolts and the catalytic converter support bracket.
45. Remove the 6 bolts and the catalytic converter heat shield.
46. Remove and discard the 7 catalytic converter-to-engine nuts.
47. Position aside the catalytic converter and support with mechanic's wire. Remove and discard the catalytic converter gasket.
48. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
49. Disconnect the upper radiator hose, the heater hose from the coolant bypass.
50. Disconnect the heater hose from the coolant tube.
51. Disconnect the throttle control electrical connector.
52. Remove the transaxle fluid level indicator.
53. Detach the wire harness retainer from the transaxle fluid indicator tube.
54. Remove the transaxle fluid indicator tube bolt.
55. Remove the transaxle fluid indicator tube bracket bolt and the transaxle fluid indicator tube.
56. Remove the 2 bolts and the transaxle roll restrictor.
57. Remove the 2 lower bellhousing-to-oil pan bolts.
58. Remove the 2 oil pan-to-bellhousing bolts.
59. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
60. Remove the 2 engine mount nuts.
61. Remove the 2 bolts, stud bolt and the engine mount.
62. Remove the 5 transaxle mount nuts and the transaxle mount plate.
63. Lower the engine and transaxle assembly from the vehicle.
64. Remove the nut for the HO2S and CMS wire connector bracket.
65. Remove the nut and position the HO2S and CMS wire connector bracket aside.
66. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
67. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
68. Disconnect the A/C compressor electrical connector.
69. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
70. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.
71. Disconnect the CKP sensor electrical connector.
72. Remove the 2 nuts and disconnect the starter motor electrical terminals.
73. Detach the starter wire harness retainer from the starter motor stud bolt.
74. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.
75. Remove the bolt and the engine ground wire.
76. Remove the 2 power steering tubes and the wiring harness as an assembly.
77. Remove the bolt, stud bolt and the starter.
78. Remove the starter isolator.
79. Remove the 4 torque converter nuts.
80. Remove and discard the 7 catalytic converter manifold studs.
81. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle assembly from the lift table.
82. Remove the 2 bellhousing-to-engine bolts, 2 stud bolts and separate the engine and transmission.
83. Install the Torque Converter Retainer, to prevent damage to the torque converter.

Engine - Manual Transaxle

SPECIAL TOOLS Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Torque Converter Holding Tool 307-346 (T97T-7902-A) Universal Adapter Brackets 014-0001 or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-357126) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-357136) article.
4. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
5. Disconnect the crankcase vent tube from the valve cover.
6. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
7. Disconnect the positive battery cable nut.
8. Detach the 2 positive battery cable wire harness retainers.
9. Remove the bolt and the negative battery cable ground.
10. 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-357165) article.
11. Disconnect the Evaporative Emission (EVAP) tube and position aside. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
12. Disconnect the power brake booster vacuum tube. Depress the quick connect locking ring. Pull the vacuum tube out of the quick connect fitting.
13. Detach the brake booster vacuum hose retainer.
14. Detach and disconnect the 2 engine harness electrical connectors.
15. Detach the engine harness from the coolant outlet bracket harness retainer.
16. Disconnect the 3 PCM electrical connectors.
17. Disconnect the starter wire harness electrical connector.
18. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) connectors and detach the wire harness retainer.
19. Pressing the locking tab, disconnect the gearshift cables from the transaxle. Disconnect the shift cable from the shift mass. Disconnect the selector cable from the selector lever.
20. Remove the gearshift levers from the bracket. Disconnect the shift cable from the retaining bracket by pulling the abutment sleeves rearward. Disconnect the selector cable from the retaining bracket by pulling the abutment sleeve rearward.
21. Remove the clip, then disconnect the clutch hydraulic line.
22. Disconnect the hydraulic clutch line and grommet from the retaining bracket.
23. Remove the engine oil level indicator.
24. Remove the bolt and the radio capacitor ground cable.
25. Remove the 2 front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
26. Remove the retainers and the splash shield.
27. Remove the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
28. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
29. Detach the 4 B+ battery cable wire harness retainers (2 shown in illustration) and position aside.
30. Remove the 2 A/C tube nuts.
31. Remove the nut and the A/C tube bracket from the A/C compressor stud bolt.
32. Disconnect the A/C tubes from the compressor. Discard the 2 O-ring seals.
33. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
34. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
35. Disconnect the lower radiator hose from the radiator.
36. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
37. Remove the engine oil filter and discard.
38. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-357140) article.
39. Remove the bolt and the power steering tube clip.
40. Remove the bolt and the power steering tubes from the steering gear. Discard the 2 power steering tube O-ring seals.
41. Remove the 2 nuts and disconnect the flexpipe from the catalytic converter. Remove and discard the nuts and gasket.
42. Remove the 2 catalytic converter support bracket-to-engine bolts.
43. Remove the 2 bolts and the catalytic converter support bracket.
44. Remove the 6 bolts and the catalytic converter heat shield.
45. Remove and discard the 7 catalytic converter-to-engine nuts.
46. Position aside the catalytic converter and support with mechanic's wire. Remove and discard the catalytic converter gasket.
47. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
48. Disconnect the upper radiator hose and the heater hose from the coolant bypass.
49. Disconnect the heater hose from the coolant tube.
50. Disconnect the throttle control electrical connector.
51. Remove the 2 bolts and the transaxle roll restrictor.
52. Remove the 2 lower bellhousing-to-oil pan bolts.
53. Remove the 2 oil pan-to-bellhousing bolts.
54. Using the Powertrain Lift and Universal Adapter Brackets, fasten the engine to the lift table.
55. Remove the 2 engine mount nuts.
56. Remove the 2 bolts, stud bolt and the engine mount.
57. Remove the 5 transaxle mount nuts and the transaxle mount plate.
58. Lower the engine and transaxle assembly from the vehicle.
59. Remove the nut for the HO2S and CMS wire connector bracket.
60. Remove the nut and position the HO2S and CMS wire connector bracket aside.
61. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
62. Disconnect the reversing lamp switch electrical connector.
63. Disconnect the A/C compressor electrical connector.
64. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
65. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.
66. Disconnect the CKP sensor electrical connector.
67. Remove the 2 nuts and disconnect the starter motor electrical terminals.
68. Detach the starter wire harness retainer from the starter motor stud bolt.
69. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.
70. Remove the bolt and the engine ground wire.
71. Remove the 2 power steering tubes and the wiring harness as an assembly.
72. Remove the bolt, stud bolt and the starter.
73. Remove the starter isolator.
74. Remove and discard the 7 catalytic converter manifold studs.
75. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle assembly from the lift table.
76. Remove the 3 bellhousing-to-engine bolts, 2 stud bolts and separate the engine and transmission.

SPECIAL TOOLS Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-00232 or equivalent Heavy Duty Floor Crane 014-00071 or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Holding Tool, Flywheel 303-103 (T74P-6375-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 20

Scheme 21

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

Vehicles equipped with a manual transaxle

1. Remove the 7 bolts, clutch pressure plate and clutch disc.
2. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Loosen the bolt and remove the accessory drivebelt idler pulley.
5. Remove the 3 bolts and the coolant pump pulley.
6. Remove the 3 bolts and the coolant pump.
7. Disconnect the heater hose and lower radiator hose from the thermostat housing.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
9. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
10. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
11. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
12. Disconnect the 4 fuel injector electrical connectors and detach the wiring harness retainers from valve cover stud bolts and intake manifold.
13. Remove the 2 bolts and the fuel rail with the fuel injectors.
14. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
16. If equipped, disconnect the swirl control valve solenoid electrical connector.
17. Disconnect the EGR valve electrical connector and if equipped, disconnect the swirl control valve sensor electrical connector.
18. Remove the bolt and the oil level indicator tube. Discard the O-ring seal.
19. Remove the lower intake manifold bolt.
20. Loosen the 2 intake manifold bolts.
21. Remove the 5 intake manifold bolts.
22. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. Remove the intake manifold.
23. Remove the EGR tube.
24. Remove the radio interference capacitor bracket bolt and position the bracket aside.
25. Disconnect the EGR valve coolant hose.
26. Disconnect the coolant bypass hose.
27. Remove the 4 bolts and the coolant outlet.
28. Disconnect the coolant bypass hose.
29. Remove the 3 bolts, thermostat housing and thermostat.
30. Remove the 2 bolts, stud bolt and the A/C compressor.
31. Remove the bolt and the KS.
32. Remove the 8 bolts and the crankcase vent oil separator.
33. If equipped, remove the engine block heater.
34. Remove the 4 bolts and the ignition coil-on-plugs.
35. Remove the spark plugs and the CHT sensor.
36. Remove the bolts and the valve cover.
37. 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.
38. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
39. Remove the engine plug bolt.
40. Assemble the Drive Pinion Flange Holding Fixture and Adapter using 4 hardened washers in the locations shown in illustration.
41. Using the Drive Pinion Flange Holding Fixture and Adapter 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.
42. Using the Oil Seal Remover, remove the crankshaft front seal.
43. Remove the 2 bolts and the CKP sensor.
44. Remove the 22 bolts and the engine front cover.
45. 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.
46. Remove the RH timing chain guide.
47. Remove the timing chain.
48. Remove the 2 bolts and the LH timing chain guide.
49. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
50. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
51. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
52. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
53. Remove the camshafts from the engine. Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.
54. Remove the valve tappets.
55. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
56. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
57. Remove the cylinder head alignment dowels.
58. Remove the 13 bolts and the oil pan.
59. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
60. Remove the 2 bolts, oil pump pickup tube and gasket. Discard the gasket.
61. Remove the 4 bolts and the oil pump.