Engine - 2.3L: Removal & Installation Ford Fusion I facelift

REMOVAL AND INSTALLATION

All vehicles

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
4. Remove the bolt, 2 nuts and the generator air inlet duct. To install, tighten to 6 Nm (53 lb-in).
5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
6. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
7. Disconnect the 2 swirl control valve electrical connectors.
8. Detach the 2 wiring harness pin-type retainers and remove the fuel rail insulator.
9. Detach the electrical connector pin-type retainer.
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
12. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
13. Remove the 3 bolts and position the AIR pump aside. To install, tighten to 30 Nm (22 lb-ft).
14. Disconnect the vacuum hose from the intake manifold.
15. Detach the radiator hose retaining clip from the intake manifold.
16. Remove the intake manifold lower bolt. To install, tighten to 18 Nm (159 lb-in).
17. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
18. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
19. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. Detach the wiring harness pin-type retainer and position the wiring harness aside.
20. Remove the nut and the S-terminal wire from the starter. To install, tighten to 12 Nm (106 lb-in).
21. Disconnect the Throttle Body (TB) electrical connector.
22. Remove the 4 bolts and position the TB aside. To install, tighten to 10 Nm (89 lb-in).
23. Detach the 2 pin-type retainers from the intake manifold.
24. Remove the 7 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. To install, tighten to 18 Nm (159 lb-in).
25. Release the clamp and disconnect the crankcase vent hose.
26. Detach the Knock Sensor (KS) electrical connector pin-type retainer.
27. Remove the EGR tube. To install, tighten to 55 Nm (41 lb-ft).
28. Remove the intake manifold and discard the gaskets. To install, tighten to 18 Nm (159 lb-in).
29. To install, reverse the removal procedure. Install new TB and intake manifold gaskets.

REMOVAL

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

1. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-291905) article.
2. Remove the engine wiring harness bracket from the valve cover stud.
3. Remove the oil level indicator.
4. Disconnect the crankcase vent hose.
5. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
6. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
7. Disconnect the Camshaft Position (CMP) sensor electrical connector.
8. Detach all of the wiring harness retainers from the valve cover and the valve cover studs.
9. Remove the 14 valve cover retainers and the valve cover. Discard the gasket.

INSTALLATION

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown.
3. Install the valve cover, new gasket and retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the wiring harness and attach all of the wiring harness retainers to the valve cover and the valve cover studs.
5. Connect the CMP sensor electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the VCT solenoid electrical connector.
8. Connect the crankcase vent hose.
9. Install the oil level indicator.
10. Position the engine wiring harness bracket on the valve cover stud.
11. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-291905) article.

Scheme 9

1. For additional information, refer to the procedures.

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-291902-S41305063352008073000000) .
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 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
8. Remove the engine plug bolt.
9. Install the Crankshaft TDC Timing Peg.
10. Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.
11. 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.

All vehicles

1. Install a new diamond washer.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
4. Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.
5. 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).
6. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
7. Remove the Crankshaft TDC Timing Peg.
8. Remove the Camshaft Alignment Plate.
9. Turn the crankshaft clockwise 1 and 3/4 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 (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
13. Install the 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 (0.23 in) x 18 mm (0.7 in) bolt.
16. Remove the Crankshaft TDC Timing Peg.
17. Install the engine plug bolt. To install, tighten to 20 Nm (177 lb-in).
18. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
19. If equipped, install the underbody cover and the 7 screws.
20. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
21. Install the valve cover. For additional information, refer to «Valve Cover»(ref-291902-S41305063352008073000000) .

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.

1. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-291902-S23668799482008073000000) .
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 «Crankshaft Pulley»(ref-291902-S23668799482008073000000) .

Scheme 10

1. For additional information, refer to the procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(ref-291891) .
3. Remove the 6 bolts and the flexplate.

1. Install the flexplate and tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(ref-291891) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the clutch. For additional information, refer to «CLUTCH»(ref-291906) article.
3. Remove the 6 bolts and the flywheel.

1. Install the flywheel and tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the clutch and manual transaxle. For additional information, refer to «CLUTCH»(ref-291906) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-291902-S35834189832008073000000) or «Flywheel»(ref-291902-S04372721572008073000000) .
3. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
4. Remove the 17 bolts and the oil pan.
5. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear oil seal with retainer plate and bolts. To install, tighten in the sequence shown to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan, engine front cover and cylinder block mating surfaces.
4. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
5. Install the 4 bolts. To install, tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 20 Nm (177 lb-in).
7. Install the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-291902-S35834189832008073000000) or «Flywheel»(ref-291902-S04372721572008073000000) .
8. Fill the engine with clean engine oil.

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

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the accessory drive belt and idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) .
4. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-291902-S23668799482008073000000) .
5. If equipped, remove the 7 screws and the underbody cover.
6. Remove the engine mount. For additional information, refer to «Engine Mount»(ref-291902-S30765159612008073000000) .
7. Using the Oil Seal Remover, remove and discard the crankshaft front oil seal.
8. Remove the 3 bolts and the coolant pump pulley.
9. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
10. Remove the 3 power steering pump bolts and position the power steering pump aside.
11. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
12. Remove the 2 bolts and the CKP sensor. Discard the CKP sensor.
13. Remove the 22 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 (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
4. Position the power steering pump and install the 3 bolts.
5. Install the coolant pump pulley and bolts.
6. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
7. Install the engine mount. For additional information, refer to «Engine Mount»(ref-291902-S30765159612008073000000) .
8. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-291902-S23668799482008073000000) .
9. 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.
10. Install a new CKP sensor. Do not tighten the bolts at this time.
11. Adjust the new CKP sensor with the alignment tool. Tighten the bolts to 7 Nm (62 lb-in).
12. Connect the CKP sensor electrical connector.
13. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
14. If equipped, install the underbody cover and the 7 screws.
15. Install the accessory drive belt and idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
16. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-291902-S39710978172008073000000) .
3. 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.
4. Remove the timing chain tensioner arm.
5. Remove the timing chain.
6. Remove the 2 bolts and the timing chain guide.
7. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the timing chain guide and the 2 bolts. To install, tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the timing chain tensioner arm.
5. Install the timing chain tensioner and the 2 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 bolts. Tighten to 72 Nm (53 lb-ft).
7. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-291902-S39710978172008073000000) .

Scheme 11

1. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-291907) article.
2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. To install, tighten to 17 Nm (150 lb-in).
3. To install, reverse the removal procedure.

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

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

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-291907) article.
5. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-291902-S15091099072008073000000) .
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 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
9. Remove the engine plug bolt.
10. Install the Crankshaft TDC Timing Peg.
11. 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.
12. Remove the lower timing hole plug from the engine front cover.
13. Remove the upper timing hole plug from the engine front cover.
14. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate the exhaust camshaft clockwise (using the flats of the camshaft) to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
17. Remove the Camshaft Alignment Plate.
18. Remove the timing chain from the 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 the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
21. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

All vehicles

1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the 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 (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
15. If equipped, install the underbody cover and the 7 screws.
16. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
17. Install the VCT solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-291907) 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.

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

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-291907) article.
5. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-291902-S15091099072008073000000) .
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 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
9. Remove the engine plug bolt.
10. Install the Crankshaft TDC Timing Peg.
11. 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.
12. Remove the lower timing hole plug from the engine front cover.
13. Remove the upper timing hole plug from the engine front cover.
14. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate the exhaust camshaft clockwise (using the flats of the camshaft) to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
17. Remove the Camshaft Alignment Plate.
18. Remove the timing chain from the intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the intake camshaft from the engine. Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the intake camshaft.
21. Mark the camshaft phaser and sprocket and the camshaft for reference during installation.
22. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

All vehicles

1. Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the intake camshaft bearing cap bolts until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the 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 (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
15. If equipped, install the underbody cover and the 7 screws.
16. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
17. Install the VCT solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-291907) article.

Scheme 12

1. For additional information, refer to the procedures.

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-291902-S24228610712008073000000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-291905) article.
5. Connect compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-291905) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «Camshafts»(ref-291902-S24228610712008073000000) .

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-291902-S24228610712008073000000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-291905) article.
5. Connect compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the 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 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 - 2.3L»(ref-291905) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «Camshafts»(ref-291902-S24228610712008073000000) .

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-291902-S24228610712008073000000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
3. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-291902-S15091099072008073000000) .
4. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
5. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
6. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-291858) article.
7. Remove the fuel supply rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-291909) article.
8. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-291902-S11717303832008073000000) .
9. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
10. Remove the 3 bolts and position the AIR pump aside.
11. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
12. Remove the engine mount bracket bolt.
13. Install the Engine Lifting Brackets and a suitable length of chain to the threaded hole in the LH side of the engine block.
14. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
15. Remove the nut, 2 bolts and the engine mount.
16. Lower the engine 25 mm (0.98 in).
17. Remove the 2 nuts and the engine mount bracket.
18. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(ref-291902-S42373217732008073000000) .
19. Remove the Camshaft Alignment Plate.
20. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
21. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
22. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
23. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
24. Detach the retaining clip and position the Evaporative Emission (EVAP) tube bundle aside.
25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
26. Disconnect the engine Engine Coolant Temperature (ECT) electrical connector.
27. Disconnect the EGR valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
29. Remove the 2 bolts and position the AIR valve bracket aside.
30. Remove the 10 bolts and the cylinder head. Discard the bolts.

All vehicles

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. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 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.
7. Position AIR valve bracket and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Connect the coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Connect the ECT electrical connector.
11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
12. Attach the EVAP tube bundle retaining clip retaining clip.
13. Install the valve tappets.
14. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stages 1: Tighten the camshaft bearing cap bolts until finger tight. Stages 2: Tighten to 7 Nm (62 lb-in). Stages 3: Tighten to 16 Nm (142 lb-in).
15. Install the Camshaft Alignment Plate.
16. Install the VCT solenoid and bolt. Tighten to 10 Nm (89 lb-in).
17. Install the timing drive components. For additional information, refer to «Timing Drive Components»(ref-291902-S42373217732008073000000) .
18. Install the engine mount bracket and the 2 nuts. Tighten to 103 Nm (76 lb-ft).
19. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
20. Install the engine mount, nut and 2 bolts. Tighten to 55 Nm (41 lb-ft).
21. Lower the engine 25 mm (0.98 in).
22. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
23. Install the radio frequency interference capacitor and bolt to the engine mount bracket. Tighten to 10 Nm (89 lb-in).
24. Install the AIR pump and the 3 bolts. Tighten to 30 Nm (22 lb-ft).
25. Connect the AIR pump electrical connector.
26. Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-291902-S11717303832008073000000) .
27. Install the fuel supply rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-291909) article.
28. Install the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-291858) article.
29. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
30. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
31. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.

Scheme 13

Note. Automatic transmission shown, manual transmission similar.

Scheme 14

Scheme 15

Scheme 16

1. For additional information, refer to the procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. If equipped, remove the 2 screws and the oil filter access cover.
3. Loosen the oil filter drain plug.
4. Using a cup-style oil filter wrench, loosen the oil filter cover one turn.
5. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter. Remove and discard the oil filter drain plug O-ring seal.
6. Remove the oil filter cover and oil filter element. Discard the oil filter element. Remove and discard the oil filter cover O-ring seal.

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

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. If equipped, remove the 7 screws and the underbody cover.
3. Remove the oil filter element. For additional information, refer to «Oil Filter Element»(ref-291902-S35305270342008073000000) .
4. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
5. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
6. Remove the 3 bolts and position the AIR pump aside. To install, tighten to 30 Nm (22 lb-ft).
7. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
8. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
9. To install, reverse the removal procedure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. If equipped, remove the 7 screws and the underbody cover.
3. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
6. To install, reverse the removal procedure. Apply thread sealant to the EOP switch threads.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
4. Loosen the 3 upper transaxle-to-engine bolts 5 mm (0.19 in).
5. If equipped, remove the 7 screws and the underbody cover.
6. Loosen the 1 (automatic transmission) or 2 (manual transmission) front lower bellhousing-to-engine bolt(s) 5 mm (0.19 in).
7. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Remove the bellhousing-to-oil pan bolt.
10. Slide the transmission rearward 5 mm (0.19 in).
11. Drain the engine oil. Install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
12. Remove the 4 engine front cover-to-oil pan bolts.
13. Remove the 13 bolts and the oil pan.

All vehicles

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
6. Alternate tightening the 1 front and 1 rear lower bolts to slide the transmission and engine together. Tighten to 48 Nm (35 lb-ft).
7. Tighten the remaining front lower bolt (manual transmission) and rear lower stud bolt. Tighten to 48 Nm (35 lb-ft).
8. Install the bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
9. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
10. If equipped, install the underbody cover and the 7 screws.
11. Tighten the 3 top bellhousing-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
13. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
14. 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-291849) article.
2. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-291902-S10172228372008073000000) and «Oil Pan»(ref-291902-S11504448882008073000000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-291902-S39710978172008073000000) .
3. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 3 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.
6. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
7. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
8. Remove the chain from the oil pump sprocket.
9. Remove the bolt and oil pump sprocket.
10. Remove the 4 bolts and the oil pump.

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump 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 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.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
11. Install the 3 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-291902-S39710978172008073000000) .
13. 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-291849) article.
2. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
3. Install the Engine Support Bar to the front and rear engine lifting eyes.
4. Remove the bolt and the radio frequency interference capacitor. To install, tighten to 10 Nm (89 lb-in).
5. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
6. Use the Engine Support Bar to raise the engine 25 mm (0.98 in).
7. Remove the 2 engine mount bracket nuts. To install, tighten to 103 Nm (76 lb-ft).
8. Remove the nut, 2 bolts and the engine mount. To install, tighten to 55 Nm (41 lb-ft).
9. Use the Engine Support Bar to lower the engine 25 mm (0.98 in). Remove the engine mount bracket.
10. To install, reverse the removal procedure.

Engine - Automatic Transaxle

Special Tools Illustration Tool Name Tool Number Adapter for 204-592 204-592/1 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Remover, Halfshaft 205-243 (Part of 205-241) Remover, Halfshaft 205-832 Remover, Tie-Rod End 211-105 Separator, Ball Joint 204-592 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
4. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-291859) article.
5. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Remove the 2 nuts and the steering joint cover.
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
8. Remove the bolt and disconnect the Power Steering Pressure (PSP) tube from the power steering pump. Route the PSP tube out the bottom of the engine compartment.
9. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
13. Remove the engine roll restrictor bolt.
14. Remove the 4 screws and position the RH fender splash shield aside.
15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
16. Remove the 4 screws and position the LH fender splash shield aside.
17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
18. Remove the cotter pins and nuts from the tie-rod ends.
19. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
20. Disconnect the power steering cooler tube.
21. Remove the nuts and separate the sway bar links from the struts.
22. Remove the lower ball joint nuts.
23. Using the Ball Joint Separator and Adapter, separate the lower ball joints from the lower control arms.
24. Remove the through bolts from the lower control arms.
25. Position the Powertrain Lift under the subframe assembly.
26. Remove the subframe bracket-to-body bolts.
27. Remove the subframe nuts and the subframe brackets.
28. Remove the front subframe nuts.
29. Lower the subframe assembly from the vehicle.
30. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
31. Remove the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-291902-S10172228372008073000000) and «Oil Filter Element»(ref-291902-S35305270342008073000000) .
32. Remove the bolt, 2 nuts and the generator air inlet duct.
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
34. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
35. Remove the nut and disconnect the wire from the battery cable.
36. Disconnect the 2 engine wiring harness electrical connectors.
37. Remove the bolt and the ground wire.
38. Disconnect the PCM electrical connector and the pin-type retainer.
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
40. Disconnect the crankcase vent tube from the valve cover.
41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
42. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
43. Detach the retaining clip and position the EVAP tube bundle aside.
44. Disconnect the upper radiator and heater hoses from the coolant bypass.
45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
46. Disconnect the heater hose in-line connector.
47. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
48. Disconnect the transaxle cooler tubes.
49. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
50. Detach the coolant vent hose retaining clip from the A/C tube.
51. Disconnect the power steering cooler tube.
52. Remove the 2 A/C tube bracket bolts.
53. Remove the 2 nuts and disconnect the A/C tubes.
54. Remove the nut and disconnect the A/C tube from the condenser.
55. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
56. Remove the retaining clip and disconnect the lower radiator hose.
57. Using the Halfshaft Removers and Slide Hammer, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
58. Remove the 2 RH halfshaft carrier bearing bracket bolts.
59. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
60. Remove the bellhousing-to-oil pan bolt.
61. Remove the 2 oil pan-to-bellhousing bolts.
62. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
63. Remove the 3 bolts and position the AIR pump aside.
64. Install the Powertrain Lift and Universal Adapter Brackets onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
65. Remove the 2 transaxle mount bolts.
66. Remove the bolt, 2 nuts and the engine mount bracket.
67. Lower the engine and transaxle from the vehicle.
68. Remove the 2 nuts and disconnect the starter wires.
69. Detach the 2 wiring harness retainers from the starter stud bolts.
70. Remove the 2 stud bolts and the starter.
71. Remove the 4 torque converter nuts.
72. Remove the bolt and transaxle ground wire.
73. Remove the nut and position the engine wiring harness bracket aside.
74. Disconnect the Transmission Range (TR) sensor and primary control solenoid electrical connectors.
75. Disconnect the transaxle control electrical connectors.
76. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
77. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
78. Disconnect the transaxle pressure switch electrical connector.
79. Install the Heavy Duty Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
80. Remove the bellhousing-to-engine retainers. Separate the engine and transaxle.

Engine - Manual Transaxle

Special Tools Illustration Tool Name Tool Number Adapter for 204-592 204-592/1 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Remover, Halfshaft 205-243 (Part of 205-241) Remover, Halfshaft 205-832 Remover, Tie-Rod End 211-105 Separator, Ball Joint 204-592 Slide Hammer 100-001 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
4. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-291859) article.
5. Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Remove the 2 nuts and the steering joint cover.
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
8. Remove the bolt and disconnect the Power Steering Pressure (PSP) tube from the power steering pump. Route the PSP tube out the bottom of the engine compartment.
9. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-291897) article.
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
13. Remove the engine roll restrictor bolt.
14. Remove the 4 screws and position the RH fender splash shield aside.
15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
16. Remove the 4 screws and position the LH fender splash shield aside.
17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
18. Remove the cotter pins and nuts from the tie-rod ends.
19. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
20. Disconnect the power steering cooler tube.
21. Remove the nuts and separate the sway bar links from the struts.
22. Remove the lower ball joint nuts.
23. Using the Ball Joint Separator and Adapter, separate the lower ball joints from the lower control arms.
24. Remove the through bolts from the lower control arms.
25. Position the Powertrain Lift under the subframe assembly.
26. Remove the subframe bracket-to-body bolts.
27. Remove the rear subframe nuts and the subframe brackets.
28. Remove the front subframe nuts.
29. Lower the subframe assembly from the vehicle.
30. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
31. Remove the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-291902-S10172228372008073000000) and «Oil Filter Element»(ref-291902-S35305270342008073000000) .
32. Remove the bolt, 2 nuts and the generator air inlet duct.
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article.
34. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
35. Remove the nut and disconnect the wire from the battery cable.
36. Disconnect the 2 engine wiring harness electrical connectors.
37. Remove the bolt and the ground wire.
38. Disconnect the PCM electrical connector and pin-type retainer.
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-291908) article.
40. Disconnect the crankcase vent tube from the valve cover.
41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
42. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
43. Detach the retaining clip and position the EVAP tube bundle aside.
44. Disconnect the upper radiator and heater hoses from the coolant bypass.
45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
46. Disconnect the heater hose in-line connector.
47. Remove the 2 clutch tube bracket bolts.
48. Remove the 2 bolts and position the clutch slave cylinder aside.
49. Disconnect the transaxle control cables from the control levers. Detach the control cables from the bracket.
50. Disconnect the power steering cooler tube.
51. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
52. Detach the coolant vent hose retaining clip from the A/C tube.
53. Remove the 2 A/C tube bracket bolts.
54. Remove the 2 nuts and disconnect the A/C tubes.
55. Remove the nut and disconnect the A/C tube from the condenser.
56. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
57. Remove the retaining clip and disconnect the lower radiator hose.
58. Using the Halfshaft Removers and Slide Hammer, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
59. Remove the 2 RH halfshaft carrier bearing bracket bolts.
60. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
61. Remove the bellhousing-to-oil pan bolt.
62. Remove the 2 oil pan-to-bellhousing bolts.
63. Install the Powertrain Lift and Universal Adapter Brackets onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
64. Remove the 2 transaxle mount bolts.
65. Remove the bolt, 2 nuts and the motor mount bracket.
66. Lower the engine and transaxle from the vehicle.
67. Remove the 2 nuts and disconnect the starter wires.
68. Detach the 2 wiring harness retainers from the starter stud bolts.
69. Remove the 2 bolts and the starter.
70. Remove the bolt and transaxle ground wire.
71. Remove the nut and position the engine wiring harness bracket aside.
72. Disconnect the backup lamp electrical connector.
73. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
74. Install the Heavy Duty Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
75. Remove the bellhousing-to-engine retainers. Separate the engine and transaxle.

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 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Timing Peg, Crankshaft TDC 303-507

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.

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

Note. For additional information, refer to the exploded views under the ASSEMBLY .

Vehicles with manual transaxle

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Remove the 6 bolts, clutch pressure plate and clutch disc.
2. Remove the starter motor isolator.
3. Remove the 6 bolts and the flywheel.
4. Remove the 6 bolts and the flexplate.
5. Mount the engine on a suitable Engine Stand.
6. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
7. Remove the accessory drive belt from the engine.
8. Remove the 2 bolts and the tensioner.
9. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
10. Remove the 2 upper power steering pump bolts.
11. Remove the lower bolt and the power steering pump.
12. Disconnect the Knock Sensor (KS) electrical connector and the 2 harness pin-type retainers.
13. Disconnect the lower radiator and heater hoses from the thermostat housing. Detach the radiator hose retainer clip from the intake manifold.
14. Disconnect the coolant hose from the throttle body and remove the hose from the engine.
15. Disconnect the A/C compressor electrical connector.
16. Remove the bolt and the A/C manifold.
17. Remove the 3 bolts and the A/C compressor.
18. Remove the 3 bolts and the coolant pump pulley.
19. Remove the 3 bolts and the coolant pump. Remove and discard the O-ring seal.
20. Remove the bolt and the accessory drive belt idler pulley.
21. Disconnect the Crankshaft Position (CKP) sensor electrical connector and harness pin-type retainer.
22. Remove the 2 bolts and the CKP sensor. Discard the CKP sensor.
23. Remove the 2 nuts and the generator splash shield.
24. Pull back the rubber boot and remove the nut. Disconnect the generator electrical connections and pin-type retainer.
25. Remove the bolt, 2 stud bolts and the generator.
26. Disconnect the Secondary Air Injection (AIR) hose from the catalytic converter.
27. Disconnect the AIR valve vacuum supply tube from the intake manifold.
28. Disconnect the AIR valve electrical connector.
29. Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.
30. Disconnect the catalyst monitor sensor electrical connector(s).
31. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
32. Remove the wiring harness bracket from the valve cover stud.
33. Detach the wiring harness retainer from the valve cover stud.
34. Remove the 6 screws and the catalytic converter heat shield.
35. Remove the 2 catalytic converter bracket-to-catalytic converter bolts.
36. Remove the 7 nuts, catalytic converter, gasket and the 7 studs. Discard the nuts, gasket and the studs.
37. If equipped, disconnect the block heater electrical connector.
38. If equipped, remove the block heater.
39. Remove the 2 bolts and the catalytic converter bracket.
40. Disconnect the coolant temperature sender electrical connector.
41. Disconnect the EGR coolant hose and electrical connector.
42. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
43. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
44. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.
45. Disconnect the 2 swirl control valve electrical connectors.
46. Detach the 2 wiring harness pin-type retainers from the intake manifold.
47. Disconnect the electronic Throttle Body (TB) electrical connector.
48. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. Discard the gaskets.
49. Disconnect the PCV hose and remove the intake manifold.
50. Remove the EGR tube.
51. Remove the 3 bolts and the thermostat housing.
52. Disconnect the bypass hose from the cylinder block fitting.
53. Disconnect the bypass hose from the coolant outlet and remove the bypass hose from the engine.
54. Remove the bolt and the KS.
55. Remove the 8 bolts and the crankcase vent oil separator. Discard the gasket.
56. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
57. Disconnect the Camshaft Position (CMP) sensor electrical connector.
58. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
59. Disconnect the 4 coil-on-plug electrical connectors.
60. Pull back the boot and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
61. Detach the 2 pin-type harness retainers and remove the fuel supply rail insulator.
62. Disconnect the 4 fuel injector electrical connectors.
63. Detach the remaining wiring harness retainers and remove the wiring harness from the engine.
64. Remove the 2 bolts and the fuel rail and injector assembly.
65. Remove the 4 bolts and the 4 coil-on-plug assemblies.
66. Remove the oil level indicator.
67. Loosen the 14 retainers and remove the valve cover. Discard the gaskets.
68. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
69. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
70. Remove the engine plug bolt.
71. Install the Crankshaft TDC Timing Peg.
72. Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.
73. 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.
74. Using the Oil Seal Remover, remove the crankshaft front oil seal.
75. Remove the 22 bolts and the engine front cover.
76. 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.
77. Remove the RH timing chain guide.
78. Remove the timing chain.
79. Remove the 2 bolts and the LH timing chain guide.
80. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
81. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
82. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
83. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
84. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
85. Remove the bolt and the VCT solenoid.
86. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
87. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856) article.
88. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
89. Remove the 2 cylinder head alignment dowels.
90. Remove the 13 bolts and the oil pan.
91. Remove the 6 bolts and the rear crankshaft seal.
92. Remove the 2 bolts, oil pump pickup tube and gasket.
93. Remove the 4 bolts and the oil pump.
94. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center (TDC). Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. see scheme 415: Installing Crankshaft TDC Timing Peg
95. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. see scheme 416: Locating Balancer Unit And Shafts Reference Mark
96. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. see scheme 417: Locating Balancer Unit Bolts
97. Remove the Crankshaft TDC Timing Peg. see scheme 418: Installing Crankshaft TDC Timing Peg
98. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
99. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly. Remove the connecting rod cap bolts and cap. see scheme 419: Locating Connecting Rod Cap Bolts
100. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block. see scheme 420: Identifying Connecting Rod Installer
101. Remove the bolts in the sequence shown. Remove the main bearing beam. Discard the bolts. see scheme 421: Identifying Crankshaft Cap Bolts Removing Sequence
102. Remove the crankshaft from the engine block. see scheme 422: Locating Crankshaft
103. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. Remove the main bearings from the main bearing beam. see scheme 423: Locating Main Bearings
104. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing. Remove the main bearings from the cylinder block. see scheme 424: Locating Main Bearings
105. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter. Remove the 4 oil squirters. see scheme 425: Locating Oil Squirters
106. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-291856).