Engine Mechanical - 2.5L: Removal & Installation Ford Kuga II

Removal

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

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

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658857-S21902415702014092900000) .
3. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
4. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. NOTE: Mark the location of the camshafts prior to removal. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.

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1. NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 10 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to step 11 . Place a paint mark on the crankshaft at the 12 o'clock position.
2. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
3. NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons. Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.
4. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
5. Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge Repeat to measure all of the lobe/tappet clearances.
6. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. NOTE: The nominal clearance is: intake: 0.25 mm (0.0098 in) . exhaust: 0.30 mm (0.0118 in) . NOTE: The acceptable clearances after being fully installed are: intake: 0.23-0.28 mm (0.009-0.011 in) . exhaust: 0.27-0.33 mm (0.010-0.013 in) . Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
7. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.
8. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
9. NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly. Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-507.
10. If necessary, replace any tappets with the correct tappets selected during the valve clearance check.
11. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
12. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
13. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
14. Torque : 97 lb.in (11 Nm)
15. Torque : 97 lb.in (11 Nm)
16. Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658857-S21902415702014092900000) .

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.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
3. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
4. Refer to: «VALVE COVER»(ref-658857-S20944727802014092900000) .
5. Refer to: «ACCESSORY DRIVE BELT»(ref-658866-S05124902352014092900000) .
6. NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
7. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
8. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
9. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. NOTE: Use an air impact wrench to remove the crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding .
10. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
11. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal .

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1. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
2. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
3. NOTE: Do not install the crankshaft pulley bolt at this time. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
4. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt
5. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Install a new crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding . Torque : Stage 1: 74 lb.ft (100 Nm) Stage 2: 90 °
6. Remove the General Equipment: M6 Bolt
7. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
8. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
9. NOTE: Only turn the engine in the normal direction of rotation. Turn one and three-fourths turns.
10. NOTE: Only turn the engine in the normal direction of rotation. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
11. NOTE: Only hand-tighten the bolt or damage to the front cover can occur. Install the General Equipment: M6 Bolt. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
12. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
13. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
14. Remove the General Equipment: M6 Bolt.
15. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
16. Torque : 177 lb.in (20 Nm)
17. Refer to: «ACCESSORY DRIVE BELT»(ref-658866-S05124902352014092900000) .
18. Refer to: «VALVE COVER»(ref-658857-S20944727802014092900000) .
19. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
20. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
21. After completing repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

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 may cause engine failure.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .
4. Torque : 21 lb.ft (28 Nm)
5. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) .
6. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe. Support the exhaust flexible pipe with a support wrap or suitable splint.
7. Remove the following items: Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «INTAKE MANIFOLD»(ref-658857-S34724536022014092900000) . Refer to: «FUEL INJECTORS»(ref-658909-S35496250222014092900000) . Refer to: «CAMSHAFTS»(ref-658857-S27704224222014092900000) .
8. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
9. Use the General Equipment: Hose Clamp Remover/Installer
10. Use the General Equipment: Hose Clamp Remover/Installer
11. Use the General Equipment: Hose Clamp Remover/Installer
12. Use the General Equipment: Hose Clamp Remover/Installer
13. Use the General Equipment: Hose Clamp Remover/Installer

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1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Material : Motorcraft® Metal Surface Prep/ZC-31-B Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
2. Check the cylinder head distortion. Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) .
3. Check the cylinder block distortion. Refer to: «CYLINDER BLOCK DISTORTION»(ref-658863-S42792501642014092900000) .
4. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
5. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
6. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 33 lb.ft (45 Nm) Stage 4: 90° Stage 5: 90°
7. Use the General Equipment: Hose Clamp Remover/Installer
8. Use the General Equipment: Hose Clamp Remover/Installer
9. Use the General Equipment: Hose Clamp Remover/Installer
10. Use the General Equipment: Hose Clamp Remover/Installer
11. Use the General Equipment: Hose Clamp Remover/Installer
12. Torque : 41 lb.ft (55 Nm)
13. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
14. Install the following items: Refer to: «CAMSHAFTS»(ref-658857-S27704224222014092900000) . Refer to: «FUEL INJECTORS»(ref-658909-S35496250222014092900000) . Refer to: «INTAKE MANIFOLD»(ref-658857-S34724536022014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) .
15. Torque : 150 lb.in (17 Nm)
16. Torque : 41 lb.ft (55 Nm)
17. Torque : 18 lb.ft (25 Nm)
18. Torque : 35 lb.ft (48 Nm)
19. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
20. Torque : 18 lb.ft (25 Nm)
21. Torque : 97 lb.in (11 Nm)
22. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) .
23. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
24. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
25. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .

Note. Removal steps in this procedure may contain installation details.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. If equipped.
3. Torque : 66 lb.ft (90 Nm)
4. NOTE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil pan. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
5. Torque : 59 lb.ft (80 Nm)

Installation

1. To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. If equipped.
3. Material : Thread Sealant with PTFE/TA-24-B (WSK-M2G350-A2) Torque : 133 lb.in (15 Nm)

1. 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.

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1. Refer to: «ENGINE FRONT COVER»(ref-658857-S42707169382014092900000) .
2. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert the holding pin into the hole to retain the tensioner.
3. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: Use the flats on the camshaft to prevent camshaft rotation.

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1. Torque : 89 lb.in (10 Nm)
2. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger.
3. Using a small pick, push back and hold the ratchet mechanism. Use Special Service Tool: 100-010 Remover, O-Ring Seal .
4. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
5. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
6. Torque : 89 lb.in (10 Nm) Remove the holding pin to release the piston.
7. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: Use the flats on the camshafts to prevent camshaft rotation. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
8. Refer to: «ENGINE FRONT COVER»(ref-658857-S42707169382014092900000) .

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.

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1. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
2. Refer to: «IGNITION COIL-ON-PLUG»(ref-658911-S23845636662014092900000) .
3. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
4. NOTE: The VCT solenoid seal should only be replaced if it is damaged. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
5. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean the sealing surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-A

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1. NOTE: Installation of a new VCT seal is required if a damaged seal was removed during disassembly of the engine. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
2. NOTE: Inspect and if necessary, install new valve cover gaskets.
3. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. Torque : 89 lb.in (10 Nm)
5. Torque : 80 lb.in (9 Nm)
6. Torque : 89 lb.in (10 Nm)
7. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
8. Refer to: «IGNITION COIL-ON-PLUG»(ref-658911-S23845636662014092900000) .
9. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .

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. Removal steps in this procedure may contain installation details.

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1. Refer to: «TIMING CHAIN»(ref-658857-S33035663892014092900000) .
2. Do not tighten the VCT unit and the exhaust camshaft sprocket at this time. The bolts will be tightened during the timing chain installation procedure.

1. To install, reverse the removal procedure.

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.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «CRANKSHAFT POSITION (CKP) SENSOR»(ref-658892-S33306545612014092900000) .
3. Refer to: «CRANKSHAFT FRONT SEAL»(ref-658857-S28865208612014092900000) .
4. Refer to: «ENGINE MOUNT»(ref-658857-S14430744992014092900000) .
5. NOTE

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1. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean all mating surfaces. Material : Motorcraft® Silicone Gasket Remover/ZC-30-A Material : Motorcraft® Metal Surface Prep/ZC-31-A
2. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
3. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.
4. NOTE: Torque : Stage 1: 1-18: 89 lb.in (10 Nm) Stage 2: 19: 35 lb.ft (48 Nm) Stage 3: 20: 18 lb.ft (25 Nm) Stage 4: 21-23: 35 lb.ft (48 Nm)
5. Torque : 177 lb.in (20 Nm)
6. Torque : 97 lb.in (11 Nm)
7. NOTE: Torque : 18 lb.ft (25 Nm)
8. Refer to: «ENGINE MOUNT»(ref-658857-S14430744992014092900000) .
9. Refer to: «CRANKSHAFT FRONT SEAL»(ref-658857-S28865208612014092900000) .
10. Refer to: «CRANKSHAFT POSITION (CKP) SENSOR»(ref-658892-S33306545612014092900000) .
11. After completing repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

ENGINE SPECIAL TOOLS DESCRIPTION 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW Strap Wrench Hose Clamp Remover/Installer Wooden Block

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All vehicles

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1. WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .
4. Remove the following items: Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) . Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «BATTERY TRAY»(ref-658873-S33576642202014100900000) . Refer to: «DEGAS BOTTLE»(ref-658855-S19546079632014092900000) .
5. Torque : 21 lb.ft (28 Nm)
6. Refer to: «TRANSMISSION FLUID DRAIN AND REFILL»(ref-658852-S20903781302014092900000) .
7. Refer to: «FRONT HALFSHAFT RH»(ref-658849-S24244205442014092900000) . Refer to: «FRONT HALFSHAFT LH»(ref-658849-S20048807802014092900000) .
8. Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(ref-658892-S16540857232014092900000) .
9. Refer to: «SPRING LOCK COUPLINGS»(ref-658910-S29296078092014092900000) . Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
10. Use the General Equipment: Hose Clamp Remover/Installer
11. Use the General Equipment: Hose Clamp Remover/Installer
12. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) .
13. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe. Support the exhaust flexible pipe with a support wrap or suitable splint.
14. If equipped.
15. Remove the following items: Refer to: «WINDSHIELD WASHER RESERVOIR»(ref-658896-S41686352032014092900000) . Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) . Refer to: «GENERATOR - 2.5L DURATEC (125KW/170PS)»(ref-658902-S38254099442014092900000) .
16. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
17. Use the General Equipment: Strap Wrench
18. Both sides.
19. Both sides. Vehicles without auxiliary fluid cooler
20. Vehicles with auxiliary fluid cooler
21. All vehicles
22. General Equipment: Adjustable Grip Arm Use Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Wooden Block
23. General Equipment: Adjustable Grip Arm Use Special Service Tool: 300-OTC1585AE Powertrain Lift .
24. Use the General Equipment: Hose Clamp Remover/Installer
25. Use the General Equipment: Hose Clamp Remover/Installer
26. Use the General Equipment: Hose Clamp Remover/Installer
27. NOTE: Only rotate the crankshaft in a clockwise direction or engine damage will occur. Turn the component clockwise through 90 degrees.
28. General Equipment: Spreader Bar. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
29. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
30. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
31. Install Special Service Tool: 307-566 Retainer, Torque Converter .

ENGINE SPECIAL TOOLS DESCRIPTION 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

Scheme 435

Scheme 436

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 construction of the balancer shaft assembly, it should not be disassembled.

Note. For additional information, refer to the exploded views in DESCRIPTION AND OPERATION .

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

1. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
2. General Equipment: Engine Stand
3. General Equipment: Spreader Bar Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
4. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
5. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
6. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
7. If equipped.
8. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
9. NOTE: The VCT solenoid seal should only be replaced if it is damaged. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
10. NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only. 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.
11. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
12. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
13. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding .
14. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
15. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
16. Using a small pick, release the hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.
17. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: Use the flats on the camshaft to prevent camshaft rotation.
18. NOTE: The oil pump chain sprocket must be held in place.
19. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. Remove the diamond washer.
20. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
21. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. NOTE: Mark the location of the camshafts prior to removal. Loosen one turn at a time. Repeat until all the tension is released.
22. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
23. Install new parts as necessary.
24. Check the cylinder head distortion. Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) .
25. Check the cylinder block distortion. Refer to: «CYLINDER BLOCK DISTORTION»(ref-658863-S42792501642014092900000) .
26. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
27. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC .
28. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
29. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
30. Visual check. Clean the specified component with the specified material. General Equipment: Abrasive pad.
31. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
32. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
33. NOTE: Mark the position of the parts, so they can be installed in their original positions.
34. Remove in the sequence shown below.
35. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
36. 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.
37. 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.
38. Inspect the pistons. Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .
39. Inspect the cylinder bore taper. Refer to: «CYLINDER BORE TAPER»(ref-658863-S29437916692014092900000) .