REMOVAL
- Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
- Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-268732) article.
- Disconnect the acceleration control cable from the intake manifold and throttle body (TB).
- If equipped, disconnect the speed control cable from the intake manifold and TB.
- Disconnect the throttle position (TP) sensor electrical connector.
- Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
- Disconnect the idle air control (IAC) valve electrical connector.
- Disconnect the vapor purge tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the coolant hoses.
- Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.
- Disconnect the pin-type retainer from the rear of the intake manifold.
- Remove the EGR tube support bracket bolt.
- Remove the 2 bolts from the EGR tube flange.
- Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the evaporative emissions (EVAP) tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Disconnect the knock sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.
- Remove the wiring harness push pin from the bottom of the intake manifold.
- Disconnect fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Remove the 5 bolts and the intake manifold. Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
- Remove and discard the intake manifold gaskets.
INSTALLATION
- Install new intake manifold gaskets.
- Position the intake manifold and install the 5 bolts. Tighten to 18 Nm (13 lb-ft).
- Connect the wiring push pin to the bottom of the intake manifold.
- Connect the KS connector retainer to the intake manifold and connect the electrical connector.
- Attach the electrical connectors and the fuel supply tube to the bracket and connect the EVAP tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Install the 2 EGR flange mounting bolts. Tighten to 18 Nm (13 lb-ft).
- Install the EGR tube support bracket bolt. Tighten to 10 Nm (89 lb-in).
- Position the engine wiring harness and connect the pin-type retainers.
- Connect the engine vacuum harness, brake booster hose, the crankcase breather hose and coolant hoses.
- Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Connect the MAP sensor electrical connector.
- Connect the TP sensor electrical connector.
- Connect the acceleration control cable to the intake manifold and the TB.
- If equipped, connect the speed control cable to the intake manifold and the TB.
- Install the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-268732) article.
- Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
- Remove the intake manifold assembly. For additional information, refer to «Intake Manifold»(ref-268720-S09623989932007102600000) in this article.
- Position aside the cylinder head temperature (CHT) sensor cover.
- Disconnect the CHT sensor electrical connector.
- Disconnect the engine wiring harness support bracket retainers from the valve cover studs.
- Disconnect the spark plug wires from the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-268785) article.
- Disconnect the ignition coil electrical connector.
- Remove the 4 bolts and the ignition coil and spark plug wires as an assembly.
- Disconnect the camshaft position (CMP) sensor electrical connector.
- Remove the bolt and the CMP sensor.
- Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Remove the bolts and the valve cover.
- Clean and inspect the cylinder head sealing surfaces with metal surface prep and silicone gasket remover. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
- Remove and discard the valve cover gaskets.
Scheme 2
- Install new valve cover gaskets.
- Position the valve cover and install the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
- Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-268784) article.
- Install the CMP sensor and the bolt. Tighten to 7 Nm (62 lb-in).
- Connect the CMP sensor electrical connector.
- Position the ignition coil and install the 4 bolts. Tighten to 6 Nm (53 lb-in).
- Connect the ignition coil electrical connector.
- Connect the spark plug wires to the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-268785) article.
- Install the engine wiring harness support bracket retainers onto the valve cover studs.
- Connect the CHT sensor electrical connector.
- Position back the CHT sensor boot.
- Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-268720-S09623989932007102600000) in this article.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
| CAUTION | 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 you loosen the pulley bolt. Before any repair required loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. |
| CAUTION | 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. |
Scheme 3
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Remove the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
- Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-268742) article.
- Remove the valve cover. For additional information, refer to «Valve Cover»(ref-268720-S12034747432007102600000) in this article.
- 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.
- Install the special tool in the slots on the rear of both camshafts.
- Remove the engine plug bolt.
- Install the special tool.
- Assemble the special tools using 4 hardened washers in the locations shown.
- Using the special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley.
Scheme 4
Scheme 5
Scheme 6
Scheme 7
- Install the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
- 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.
- Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Rotate an additional 90 degrees.
- Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
- Remove the special tool.
- Remove the special tool.
- Turn the crankshaft clockwise 1 and 3/4 turns.
- Install the special tool.
- Turn the crankshaft clockwise until the crankshaft contacts the special tool.
- 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.
- Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, the engine valve timing must be corrected by repeating this procedure.
- Remove the special tool.
- Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
- Remove the special tool.
- Install the timing peg plug. Tighten to 20 Nm (15 lb-ft).
- Install the valve cover. For additional information, refer to «Valve Cover»(ref-268720-S12034747432007102600000) in this article.
- Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-268742) article.
- Install the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
- Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-268720-S00990805232007102600000) in this article.
- Using the special tool, remove the crankshaft front seal.
- Using the special tool, install the crankshaft front seal.
- Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-268720-S00990805232007102600000) in this article.
- Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-268720-S00990805232007102600000) in this article.
- Disconnect the crankshaft position (CKP) sensor electrical connector and the wiring harness pin-type retainers.
- Remove and discard the CKP sensor.
- Remove the bolt and the accessory drive belt tensioner.
- Remove the 3 bolts and the water pump pulley.
- Disconnect the power steering pressure (PSP) switch electrical connector.
- Remove the 3 bolts and position the power steering pump aside.
- Using a 3-jaw puller, remove the fan drive pulley.
- Remove the bolts and the engine front cover.
- Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
Scheme 8
Scheme 9
- Install the fan drive pulley, using a nut and bolt with flat washers.
- Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
- Install the front cover and tighten the bolts in the sequence shown, to the following specifications: Tighten the 8 mm bolts to 10 Nm (89 lb-in). Tighten the 10 mm bolts to 25 Nm (18 lb-ft). Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
- Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
- Connect the power steering pressure (PSP) switch electrical connector.
- Position the water pump pulley and install the 3 bolts. Tighten to 20 Nm (15 lb-ft).
- Install the accessory drive belt tensioner and the bolt. Tighten to 50 Nm (37 lb-ft).
- Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-268720-S00990805232007102600000) in this article.
- Install a 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
- Position a new CKP sensor and loosely install the 2 bolts.
- Adjust the CKP with the alignment tool, the tool must engage a tooth of the vibration damper, and tighten the 2 mounting bolts. Tighten to 7 Nm (62 lb-in).
- Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
- Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
| CAUTION | Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur. |
Scheme 10
Scheme 11
Scheme 12
Scheme 13
- Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-268720-S03180998892007102600000) in this article.
- Compress the timing chain tensioner, and insert a paper clip into the hole. Remove the 2 bolts and the timing chain tensioner.
- Remove the RH timing chain guide.
- Remove the timing chain.
- Remove the 2 bolts and the LH timing chain guide.
- If necessary, remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.
Scheme 14
- Remove the special tool.
- If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
- If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
- Install the LH timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Install the timing chain.
- Install the RH timing chain guide.
- Position the timing chain tensioner and install the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the paper clip to release the piston.
- Install the special tool.
- Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
- Install the front cover. For additional information, refer to «Engine Front Cover»(ref-268720-S03180998892007102600000) in this article.
Scheme 15
Scheme 15: Valve Train Components - Exploded View
| Item | Part Number | Description |
| 1 | W706283 | Camshaft bearing cap bolt (20 required) |
| 2 | 6A284 | Camshaft bearing cap (10 required) |
| 3 | 6A267 | Camshaft (2 required) |
| 4 | 6500 | Valve tappet (16 required) |
| 5 | 6518 | Valve spring retainer key (16 required) |
| 6 | 6514 | Valve spring retainer (16 required) |
| 7 | 6513 | Valve spring (16 required) |
| 8 | 6517 | Valve seal (16 required) |
- For additional information, refer to the procedures in this article.
| CAUTION | Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. |
- Remove the valve tappets. For additional information, refer to «Valve Tappets»(ref-268720-S07549920862007102600000) in this article.
- Using the special tools, apply compressed air to the cylinder. Using the special tools, compress the valve springs and remove the valve spring retainer keys using some grease and a small screwdriver. Remove the valve spring retainers and the valve springs.
- Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve spring retainers keys. Disconnect and remove the air supply.
- Install the valve tappets. For additional information, refer to «Valve Tappets»(ref-268720-S07549920862007102600000) in this article.
| CAUTION | 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. |
Scheme 16
Scheme 17
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Remove the camshafts. For additional information, refer to «Camshafts»(ref-268720-S15117054242007102600000) in this article.
- Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-268738) article.
- Remove the spark plug on the cylinder being serviced and connect the compressed air supply.
- Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve spring retainer keys, using some grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
- Using the special tools, remove and discard the valve seal.
Scheme 18
Scheme 19
- Install the valve stem seal installation sleeve.
- Using the special tool, install a new valve seal.
- Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve spring retainer keys using some grease and a small screwdriver.
- Disconnect the compressed air supply and install the spark plug. Tighten to 15 Nm (11 lb-ft).
- Repeat the appropriate removal and installation steps for each of the cylinders being serviced.
- Coat the valve tappets with clean engine oil and install them in their original positions.
- Install the camshafts. For additional information, refer to «Camshafts»(ref-268720-S15117054242007102600000) in this article.
REMOVAL AND INSTALLATION
| CAUTION | 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. |
Note. Valve tappets are select fit and the valve clearance must be checked before removing the tappets. For additional information, refer to Valve Clearance Check in this article. If the valve clearance has already been checked, proceed with removal.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Remove the camshafts. For additional information, refer to «Camshafts»(ref-268720-S15117054242007102600000) in this article.
- Remove and inspect the valve tappets. For additional information refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-268738) article.
- To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.
| CAUTION | Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur. |
Scheme 20
- Remove the timing chain and sprockets. For additional information, refer to «Timing Drive Components»(ref-268720-S12026298432007102600000) in this article.
- Remove the special tool.
- Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.
- Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
- Install the timing chain and sprockets. For additional information, refer to «Timing Drive Components»(ref-268720-S12026298432007102600000) in this article.
| CAUTION | Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. |
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
- Remove the camshafts. For additional information, refer to «Camshafts»(ref-268720-S15117054242007102600000) in this article.
- Remove the exhaust manifold. For additional information, refer to «Exhaust Manifold»(ref-268720-S42419295522007102600000) in this article.
- Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-268751) article.
- Remove the coolant hose retainer clip, the stud bolt and the ground cable.
- Remove the EGR tube from the cylinder head.
- Disconnect the EGR valve electrical connector.
- Disconnect the EGR coolant hose and remove it from the hose bracket.
- Disconnect the coolant bypass hose.
- Remove the cylinder block coolant drain plug.
- Remove the 10 bolts and the cylinder head. Discard the bolts.
- Remove and discard the head gasket.
- Inspect the cylinder head mating surfaces. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-268738) article.
- Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining 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.
- Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
- Apply silicone gasket and sealant to the locations shown.
- Install a new cylinder head gasket.
- Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown, in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Tighten an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
- Install the cylinder block coolant drain plug. Tighten to 55 Nm (41 lb-ft).
- Connect the coolant bypass hose.
- Connect the EGR coolant hose.
- Connect the EGR valve electrical connector.
- Connect the EGR tube to the cylinder head. Tighten to 55 Nm (41 lb-ft).
- Position the ground strap and install the stud bolt to the cylinder head. Tighten to 10 Nm (89 lb-in).
- Install the PCV hose clips.
- Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-268751) article.
- Install the exhaust manifold. For additional information, refer to «Exhaust Manifold»(ref-268720-S42419295522007102600000) in this article.
- Install the camshafts. For additional information, refer to «Camshafts»(ref-268720-S15117054242007102600000) in this article.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
- Drain the engine oil.
- Disconnect the engine oil pressure (EOP) switch electrical connector.
- Remove the EOP switch.
- Remove and discard the oil filter.
- Remove the 4 bolts, the oil filter adapter and discard the gasket.
- Clean and inspect the engine block and the adapter gasket mounting surfaces with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
- Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
- Install a new oil filter.
- Install the EOP switch. Tighten to 15 Nm (11 lb-ft).
- Connect the EOP switch electrical connector.
- Fill the engine with clean engine oil.
- Run the engine and check for leaks.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Disconnect the engine oil pressure (EOP) switch electrical connector.
- Remove the EOP switch. To install, tighten to 15 Nm (11 lb-ft).
- To install, reverse the removal procedure.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
- Remove the oil level indicator and the 2 bolts. Tighten to 10 Nm (89 lb-in).
- Remove the oil level indicator tube and discard the O-ring seal.
- To install, reverse the removal procedure. Install a new O-ring seal.
Scheme 21
Scheme 21: Engine Lubrication Components - Exploded View
| Item | Part Number | Description |
| 1 | N621945 | LH engine support insulator nut (2 required) |
| 2 | 390066 | Transmission mount bolts (2 required) |
| 3 | W500125 | Transmission-to-oil pan bolts (4 required) |
| 4 | W500125 | Transmission-to-cylinder block bolts (7 required) |
Scheme 22
| Item | Part Number | Description |
| 1 | 6730 | Oil pan drain plug |
| 2 | W706284 | Oil pan bolt (2 required) |
| 3 | W500224 | Oil pan bolt (11 required) |
| 4 | 6675 | Oil pan |
| 5 | W706282 | Oil pump screen and pickup tube bolt (2 required) |
| 6 | 6622 | Oil pump screen and pickup tube |
| 7 | 6625 | Oil pump screen and pickup tube gasket |
Scheme 23
| Item | Part Number | Description |
| 1 | W703651 | Oil pump drive chain tensioner bolt |
| 2 | 6C271 | Oil pump drive chain tensioner |
| 3 | 6A895 | Oil pump drive chain |
| 4 | W704397 | Oil pump sprocket bolt |
| 5 | 6652 | Oil pump sprocket |
| 6 | W703647 | Oil pump bolt (4 required) |
| 7 | 6600 | Oil pump |
- For additional information, refer to the procedures in this article.
- Remove the oil pan. For additional information, refer to «Oil Pan»(ref-268720-S20500138262007102600000) in this article.
- Remove the 4 bolts and the oil pump screen and pickup tube. Discard the gasket.
- Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
- Install the oil pan. For additional information, refer to «Oil Pan»(ref-268720-S20500138262007102600000) in this article.
| CAUTION | Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur. |
Scheme 24
- Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-268720-S03180998892007102600000) in this article.
- Remove the oil pump screen and pickup tube. For additional information, refer to «Oil Pump Screen and Pickup Tube»(ref-268720-S37942234432007102600000) in this article.
- Remove the oil pump chain tensioner. Release the tension on the tensioner spring. Remove the bolt and the tensioner.
- Remove the chain from the oil pump sprocket.
- Remove the bolt and oil pump sprocket.
- Remove the 4 bolts and the oil pump.
- Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft).
- Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
- Install the chain onto the oil pump sprocket.
- Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
- Install the oil pump screen and pickup tube. For additional information, refer to «Oil Pump Screen and Pickup Tube»(ref-268720-S37942234432007102600000) in this article.
- Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-268720-S03180998892007102600000) in this article.
Scheme 25
Scheme 25: Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
| Item | Part Number | Description |
| 1 | 6379 | Flywheel/flexplate bolt (6 required) |
| 2 | 6375 | Flywheel |
| 3 | 6375 | Flexplate |
| 4 | W500212 | Crankshaft rear seal and retainer plate bolt (6 required) |
| 5 | 6K318 | Crankshaft rear seal and retainer plate |
- For additional information, refer to the procedures in this article.
Note. Engine balancing is not required. Balance weights should not be installed on the new flywheel.
Note. Special bolts are used for installation. Do not use standard bolts.
Scheme 26
- Inspect the pilot bearing. Install a new pilot bearing as necessary.
- Position the flywheel.
- Using the special tool, install 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).
- Install the clutch disc and the pressure plate. For additional information, refer to «CLUTCH»(ref-268748) article.
- Remove the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R44E AND 5R55E»(ref-268740) article.
- Using the special tool, remove the bolts and the flexplate.
- Position the flexplate.
- Using the special tool, install 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).
- Install the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R44E AND 5R55E»(ref-268740) article.
- Remove the flywheel or flexplate. For additional information, refer to «Flexplate»(ref-268720-S35463385192007102600000) or «Flywheel»(ref-268720-S38370187072007102600000) in this article.
- Remove the oil pan. For additional information, refer to «Oil Pan»(ref-268720-S20500138262007102600000) in this article.
- Remove the bolts and the crankshaft rear seal and retainer plate as an assembly.
Scheme 27
Scheme 28
- Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
- Install the 6 crankshaft rear seal with retainer plate bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
- Install the oil pan. For additional information, refer to «Oil Pan»(ref-268720-S20500138262007102600000) in this article.
- Install the flywheel or flexplate. For additional information, refer to «Flexplate»(ref-268720-S35463385192007102600000) or «Flywheel»(ref-268720-S38370187072007102600000) in this article.