Engine - 2.3L: Other Ford Fusion I facelift

Material

Material

Valve Clearance Check

1. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-291902-S41305063352008073000000) .
2. Use a feeler gauge to measure the clearance of each valve and record its location.
3. Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «Valve Train Components - Exploded View»(ref-291902-S07540288582008073000000) and «Valve Tappets»(ref-291902-S39944207592008073000000) .

Valve Cover

Material

Scheme 53

Scheme 54

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Timing Peg, Crankshaft TDC 303-507

Scheme 55

Material

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Scheme 56

Material

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 57

Material

Engine Front Cover

Special Tools Illustration Tool Name Tool Number Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Material

Scheme 58

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Camshafts

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Material

Camshaft Phaser and Sprocket

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Material

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 59

Scheme 60

Material

Valve Seals

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 61

Scheme 62

Material

Valve Tappets

Material

Cylinder Head

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Support Bar 303-F072 Lifting Brackets, Engine 303-050 (T70P-6000)

Scheme 63

Material

Scheme 64

Scheme 65

Scheme 66

Oil Filter Element

Material

Engine Oil Pressure (EOP) Switch

Material

Oil Pan

Material

Oil Pump

Material

Engine Mount

Special Tools Illustration Tool Name Tool Number Engine Support Bar 303-F072

Scheme 67

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Material

Scheme 68

Engine Block

For engine block, crankshaft and piston assembly installation procedures, refer to ENGINE BLOCK - 2.3L .

Engine (Except Block)

Special Tools Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Aligner, Clutch Disc 308-006 (T71P-7137-H) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Heavy Duty Floor Crane 014-00071 or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 69

Material

Scheme 70

Identifying Lower Engine Block Components (View 2). Scheme 71

ITEM DESCRIPTION

Scheme 72

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Scheme 74

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

All vehicles

Scheme 75

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1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Install the 4 oil squirters. Tighten to 4 Nm (35 lb-in). see scheme 436: Locating Oil Squirters
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal. see scheme 437: Identifying Measuring Directions Of Crankshaft Main Bearing Journal Diameter
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. see scheme 438: Locating Main Bearing Beam
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees. see scheme 439: Identifying Main Bearing Beam Bolts Tightening Sequence
5. Measure each crankshaft block main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts. see scheme 440: Identifying Crankshaft Block Main Bearing Bore Diameter
6. Using the chart, select the crankshaft main bearings. see scheme 441: Crankshaft Main Bearings Chart
7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts. see scheme 442: Identifying Connecting Rod Large End Bore Measuring Directions
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal. see scheme 443: Identifying Measuring Directions Of Crankshaft Connecting Rod Bearing Journal Diameters
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal. see scheme 444: Connecting Rod Bearings Chart
11. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: The center bulkhead is the thrust bearing. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block. see scheme 445: Locating Upper Crankshaft Main Bearings
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam. see scheme 446: Locating Crankshaft Main Bearings
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block. see scheme 447: Locating Crankshaft
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil. see scheme 448: Locating Main Bearing Beam Side Fit Surfaces
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. see scheme 449: Locating Main Bearing Beam
17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts. Install and tighten the 10 new main bearing beam bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees. see scheme 450: Identifying Main Bearing Beam Bolts Tightening Sequence
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary. see scheme 451: Measuring Crankshaft End Play
19. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation. see scheme 452: Identifying Piston Ring Compressor And Connecting Rod Installer
20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees. see scheme 453: Locating Connecting Rod Cap Bolts
21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC). see scheme 454: Installing Crankshaft TDC Timing Peg
22. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. NOTE: The original adjustment shims must be installed in their original position. NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. see scheme 455: Locating Balancer Unit And Shafts Reference Mark
24. Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). see scheme 456: Identifying Balancer Unit Bolts Tightening Sequence
25. Remove the Crankshaft TDC Timing Peg. see scheme 457: Installing Crankshaft TDC Timing Peg
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg. see scheme 458: Installing Crankshaft TDC Timing Peg
28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For additional information, refer to the «Balance Shaft Backlash»(ref-291902-S02775475832010040500000) procedure in this section. see scheme 459: Measuring Gear Backlash
29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
30. Remove the engine plug bolt.
31. Install the Crankshaft TDC Timing Peg.
32. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
33. Install a new gasket, oil pump pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
35. Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown. To install, tighten to 10 Nm (89 lb-in).
36. Clean and inspect all mating surfaces.
37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
38. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
39. Install the remaining oil pan bolts. Tighten in the sequence shown to 20 Nm (177 lb-in).
40. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
41. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
42. Apply silicone gasket and sealant to the locations shown.
43. Install a new head gasket.
44. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
45. Install the valve tappets.
46. 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 until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
47. Install the Variable Camshaft Timing (VCT) solenoid and the bolt. Tighten to 10 Nm (89 lb-in).
48. Install the crankshaft sprocket and new crankshaft sprocket diamond washers. The crankshaft sprocket flange must be facing away from the engine block.
49. Install the oil pump drive chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
50. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
51. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
52. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
54. Install the timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
55. Install the timing chain.
56. Install the timing chain tensioner arm.
57. Using the edge of a vise, compress the timing chain tensioner plunger.
58. Using a small pick, push back and hold the ratchet mechanism.
59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
61. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
63. Clean and inspect the mounting surfaces of the engine and the front cover.
64. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
65. Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
66. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
68. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
69. Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.
70. Install a new crankshaft pulley bolt. Using the Adapter and Drive Pinion Flange Holding Fixture 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).
71. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
72. Remove the Crankshaft TDC Timing Peg.
73. Remove the Camshaft Alignment Plate.
74. Turn the crankshaft clockwise 1 and 3/4 turns.
75. Install the Crankshaft TDC Timing Peg.
76. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
77. 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.
78. 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.
79. Remove the Camshaft Alignment Plate.
80. Install a new CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
81. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
82. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
83. Remove the Crankshaft TDC Timing Peg.
84. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
85. Clean the valve cover gasket surface with metal surface prep.
86. Apply silicone gasket and sealant to the locations shown.
87. Install the valve cover. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
88. Install the oil level indicator.
89. Install the 4 coil-on-plug assemblies 4 bolts. Tighten to 8 Nm (71 lb-in).
90. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
91. Install the fuel rail and injector assembly and the 2 bolts. Tighten to 23 Nm (17 lb-ft).
92. Position the wiring harness on the engine and attach the wiring harness retainers.
93. Connect the 4 fuel injector electrical connectors.
94. Install the fuel supply rail insulator and attach the 2 pin-type harness retainers.
95. Connect the Cylinder Head Temperature (CHT) sensor electrical connector and install the boot.
96. Connect the 4 coil-on-plug electrical connectors.
97. Connect the VCT solenoid electrical connector.
98. Connect the Camshaft Position (CMP) sensor electrical connector.
99. Install a new gasket, the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
100. Using a new gasket, install the crankcase vent oil separator and the bolts. Tighten to 10 Nm (89 lb-in).
101. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
102. Position the bypass hose on the engine and connect the bypass hose to the coolant outlet.
103. Connect the bypass hose to the cylinder block fitting.
104. Install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
105. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
106. Position the intake manifold and connect the PCV hose.
107. Install new gaskets, the intake manifold and the 8 bolts. Tighten the bolts to 18 Nm (159 lb-in).
108. Connect the electronic Throttle Body (TB) electrical connector.
109. Attach the 2 wiring harness pin-type retainers to the intake manifold.
110. Connect the 2 swirl control valve electrical connectors.
111. Connect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
112. Connect the temperature Manifold Absolute Pressure (MAP) sensor electrical connector.
113. Connect the Engine Oil Pressure (EOP) switch electrical connector.
114. Connect the EGR coolant hose and electrical connector.
115. Connect the coolant temperature sender electrical connector.
116. Install the catalytic converter bracket and the 2 bolts. Tighten to 35 Nm (26 lb-ft).
117. If equipped, install the block heater. Tighten to 21 Nm (15 lb-ft).
118. If equipped, connect the block heater electrical connector.
119. Install 7 new catalytic converter studs in the cylinder head. Tighten to 17 Nm (150 lb-in).
120. Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence shown. Stage 1: Tighten to 55 Nm (41 lb-ft). Stage 2: Tighten to 55 Nm (41 lb-ft).
121. Install the 2 catalytic converter bracket-to-catalytic converter bolts. Tighten to 20 Nm (177 lb-in).
122. Install the catalytic converter heat shield and the 6 screws. Tighten to 10 Nm (89 lb-in).
123. Attach the wiring harness retainer to the valve cover stud.
124. Attach the wiring harness bracket to the valve cover stud.
125. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
126. Connect the catalyst monitor sensor electrical connector(s).
127. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
128. Connect the AIR valve electrical connector.
129. Connect the AIR valve vacuum supply tube to the intake manifold.
130. Connect the AIR hose to the catalytic converter.
131. Install the generator, bolt and 2 stud bolts. Tighten to 47 Nm (35 lb-ft).
132. Connect the pin-type retainer, generator electrical connections and install the nut. Tighten to 6 Nm (53 lb-in). Install the rubber boot.
133. Install the generator splash shield and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
134. Connect the CKP sensor electrical connector and harness pin-type retainer.
135. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
136. Install the new O-ring, coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
137. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (177 lb-in).
138. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
139. Install the A/C manifold and the bolt. Tighten to 25 Nm (18 lb-ft).
140. Connect the A/C compressor electrical connector.
141. Position the coolant hose on the engine and connect the coolant hose to the TB.
142. Connect the lower radiator and heater hoses to the thermostat housing.
143. Connect the KS electrical connector and the 2 harness pin-type retainers.
144. Install the power steering pump and the lower bolt. Finger-tighten the bolt.
145. Install the 2 upper power steering pump bolts. Tighten all 3 power steering bolts to 25 Nm (18 lb-ft).
146. Connect the Power Steering Pressure (PSP) switch electrical connector.
147. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
148. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.
149. Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.
150. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
151. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
152. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
153. Install the starter motor isolator.
154. Lubricate the transaxle input shaft pilot bearing with front axle grease.
155. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
156. Position the clutch pressure plate and install the 6 bolts. Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.

Engine - Automatic Transaxle

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material

All vehicles

1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
3. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.
4. Connect the transaxle pressure switch electrical connector.
5. Connect the Output Shaft Speed (OSS) sensor electrical connector.
6. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
7. Connect the transaxle control electrical connectors.
8. Connect the Transmission Range (TR) sensor and primary control solenoid electrical connectors.
9. Install the engine wiring harness bracket and nut. Tighten to 20 Nm (177 lb-in).
10. Install the transaxle ground wire and bolt. Tighten to 10 Nm (89 lb-in).
11. Install new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
12. Install the starter and the 2 stud bolts. Tighten to 25 Nm (18 lb-ft).
13. Connect the starter wires and install the 2 nuts. Tighten the large nut to 12 Nm (106 lb-in). Tighten the small nut to 5 Nm (44 lb-in).
14. Attach the 2 wiring harness retainers to the starter stud bolts.
15. Raise the engine and transaxle into the vehicle.
16. Install the 2 transaxle mount bolts. Tighten to 90 Nm (66 lb-ft).
17. Install the engine mount bracket, 2 nuts and the bolt. Tighten the nuts to 103 Nm (76 lb-ft). Tighten the bolt to 115 Nm (85 lb-ft).
18. Install the Secondary Air Injection (AIR) pump and the 3 bolts. Tighten to 30 Nm (22 lb-ft).
19. Connect the AIR pump electrical connector.
20. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
21. Install the bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
22. Install the RH halfshaft into the transaxle.
23. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
24. Install a new circlip in the groove on the LH halfshaft.
25. Install LH halfshaft into the transaxle.
26. Connect the lower radiator hose and install the retaining clip.
27. Install the radio frequency interference capacitor and the bolt on the engine mount bracket. Tighten to 10 Nm (89 lb-in).
28. Connect the A/C tube to the condenser and install the nut. Tighten to 8 Nm (71 lb-in).
29. Connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
30. Install the 2 A/C tube bracket bolts. Tighten to 10 Nm (89 lb-in).
31. Attach the coolant vent hose retaining clip to the A/C tube.
32. Install the radio frequency interference capacitor, ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
33. Connect the power steering cooler tube.
34. Connect the transaxle cooler tubes.
35. Connect the transaxle control cable to the bracket. Attach the control cable to the control lever.
36. Connect the heater hose in-line connector.
37. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
38. Connect the upper radiator and heater hoses to the coolant bypass.
39. Attach the Evaporative Emission (EVAP) tube bundle retaining clip to the bracket.
40. Connect the EVAP tube to the intake manifold.
41. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
42. Connect the crankcase vent tube to the valve cover.
43. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
44. Connect the PCM electrical connector and the pin-type retainer.
45. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
46. Connect the 2 engine wiring harness electrical connectors.
47. Connect the wire and install the nut on the battery cable. Tighten to 10 Nm (89 lb-in).
48. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
49. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
50. Install the generator air inlet duct, bolt and the 2 nuts. Tighten to 6 Nm (53 lb-in).
51. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
52. Install the front subframe nuts. Tighten to 150 Nm (111 lb-ft).
53. Position the subframe brackets and install the bolts finger-tight.
54. Install the subframe nuts. Tighten to 150 Nm (111 lb-ft).
55. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
56. Install the through bolts into the lower control arms. Tighten to 103 Nm (76 lb-ft).
57. Install the lower ball joint nuts. Tighten to 200 Nm (148 lb-ft).
58. Install the sway bar links and nuts to the struts. Tighten to 40 Nm (30 lb-ft).
59. Connect the power steering cooler tube.
60. Install tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install the cotter pin.
61. Install the LH splash shield and the 6 pin-type retainers (4 shown).
62. Position the LH fender splash shield and install the 4 screws.
63. Install the RH splash shield and the 6 pin-type retainers (4 shown).
64. Position the RH fender splash shield and install the 4 screws.
65. Install the engine roll restrictor bolt. Tighten to 90 Nm (66 lb-ft).
66. Route the Power Steering Pressure (PSP) tube up into the engine compartment.
67. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body. From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the dash.
68. Install the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-291902-S10172228372008073000000) and «Oil Filter Element»(ref-291902-S35305270342008073000000) .
69. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
70. If equipped, install the underbody cover and the 7 screws.
71. Connect the PSP tube to the power steering pump and install the bolt. Tighten to 35 Nm (26 lb-ft).
72. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 23 Nm (17 lb-ft).
73. Install the steering joint cover and the 2 nuts.
74. Fill the engine with clean engine oil.
75. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
76. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
77. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-291860) article.
78. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-291859) article.

Engine - Manual Transaxle

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material

1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
3. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.
4. Connect the Vehicle Speed Sensor (VSS) electrical connector.
5. Connect the backup lamp electrical connector.
6. Install the engine wiring harness bracket and nut. Tighten to 20 Nm (177 lb-in).
7. Install the transaxle ground wire and bolt. Tighten to 10 Nm (89 lb-in).
8. Install the starter and the 2 stud bolts. Tighten to 25 Nm (18 lb-ft).
9. Connect the starter wires and install the 2 nuts. Tighten the large nut to 12 Nm (106 lb-in). Tighten the small nut to 5 Nm (44 lb-in).
10. Attach the 2 wiring harness retainers to the starter stud bolts.
11. Raise the engine and transaxle into the vehicle.
12. Install the 2 transaxle mount bolts. Tighten to 90 Nm (66 lb-ft).
13. Install the engine mount bracket, 2 nuts and the bolt. Tighten the nuts to 103 Nm (76 lb-ft). Tighten the bolt to 115 Nm (85 lb-ft).
14. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
15. Install the bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
16. Install the RH halfshaft into the transaxle.
17. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
18. Install a new circlip in the groove on the LH halfshaft.
19. Install LH halfshaft into the transaxle.
20. Connect the lower radiator hose and install the retaining clip.
21. Install the radio frequency interference capacitor and the bolt on the engine mount bracket. Tighten to 10 Nm (89 lb-in).
22. Connect the A/C tube to the condenser and install the nut. Tighten to 8 Nm (71 lb-in).
23. Connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
24. Install the 2 A/C tube bracket bolts. Tighten to 10 Nm (89 lb-in).
25. Attach the coolant vent hose retaining clip to the A/C tube.
26. Install the radio frequency interference capacitor, ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
27. Connect the power steering cooler tube.
28. Attach the transaxle control cables to the bracket. Connect the control cables to the control levers.
29. Install the clutch slave cylinder and the 2 bolts. Tighten to 22 Nm (16 lb-ft).
30. Install the 2 clutch tube bracket bolts. Tighten to 22 Nm (16 lb-ft).
31. Connect the heater hose in-line connector.
32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
33. Connect the upper radiator and heater hoses to the coolant bypass.
34. Attach the Evaporative Emission (EVAP) tube bundle retaining clip to the bracket.
35. Connect the EVAP tube to the intake manifold.
36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
37. Connect the crankcase vent tube to the valve cover.
38. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
39. Connect the PCM electrical connector and the pin-type retainer.
40. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
41. Connect the 2 engine wiring harness electrical connectors.
42. Connect the wire and install the nut on the battery cable. Tighten to 10 Nm (89 lb-in).
43. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
44. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
45. Install the generator air inlet duct, bolt and the 2 nuts. Tighten to 6 Nm (53 lb-in).
46. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
47. Install the front subframe nuts. Tighten to 150 Nm (111 lb-ft).
48. Position the subframe brackets and install the bolts finger-tight.
49. Install the subframe nuts. Tighten to 150 Nm (111 lb-ft).
50. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
51. Install the through bolts into the lower control arms. Tighten to 103 Nm (76 lb-ft).
52. Install the lower ball joint nuts. Tighten to 200 Nm (148 lb-ft).
53. Install the sway bar links and nuts to the struts. Tighten to 40 Nm (30 lb-ft).
54. Connect the power steering cooler tube.
55. Install tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install the cotter pin.
56. Install the LH splash shield and the 6 pin-type retainers (4 shown).
57. Position the LH fender splash shield and install the 4 screws.
58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
59. Position the RH fender splash shield and install the 4 screws.
60. Install the engine roll restrictor bolt. Tighten to 90 Nm (66 lb-ft).
61. Route the Power Steering Pressure (PSP) tube up into the engine compartment.
62. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body. From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the dash.
63. Install the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-291902-S10172228372008073000000) and «Oil Filter Element»(ref-291902-S35305270342008073000000) .
64. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
65. If equipped, install the underbody cover and the 7 screws.
66. Connect the PSP tube to the power steering pump and install the bolt. Tighten to 35 Nm (26 lb-ft).
67. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 23 Nm (17 lb-ft).
68. Install the steering joint cover and the 2 nuts.
69. Fill the engine with clean engine oil.
70. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
71. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
72. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-291860) article.
73. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-291859) article