Engine Mechanical - 2.3L: Removal & Installation Ford Ranger II рестайлинг

Installation

1. 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. Install 4 new intake manifold gaskets.
2. Position the intake manifold and install the 5 bolts. Tighten to 18 Nm (159 lb-in).
3. Connect the wiring pushpin to the bottom of the intake manifold.
4. Connect the KS connector retainer to the intake manifold and connect the electrical connector.
5. 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-365420) .
6. Install the 2 EGR flange mounting bolts. Tighten to 18 Nm (159 lb-in).
7. Install the EGR tube support bracket bolt. Tighten to 10 Nm (89 lb-in).
8. Position the engine wiring harness and connect the 2 pin-type retainers.
9. Connect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.
10. Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
11. Connect the MAP sensor electrical connector.
12. Connect the TP sensor electrical connector.
13. Connect the acceleration control cable to the intake manifold and the TB .
14. If equipped, connect the speed control cable to the intake manifold and the TB .
15. Position the TB shield and install the 2 bolts. Tighten to 8 Nm (71 lb-in).
16. Install the ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-365413) .
17. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .

Removal

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
2. Remove the intake manifold assembly. For additional information, refer to «INTAKE MANIFOLD»(ref-365364-S14556010532010070700000) .
3. Position aside the Cylinder Head Temperature (CHT) sensor cover.
4. Disconnect the CHT sensor electrical connector.
5. Disconnect the engine wiring harness support bracket retainers from the valve cover studs.
6. Disconnect the spark plug wires from the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-365418) .
7. Disconnect the ignition coil electrical connector.
8. Remove the 4 bolts and the ignition coil and spark plug wires as an assembly.
9. Disconnect the Camshaft Position (CMP) sensor electrical connector.
10. Remove the bolt and the CMP sensor.
11. Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
12. Remove the 10 bolts, the 4 stud bolts and the valve cover.
13. 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 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.
14. Remove and discard the 4 valve cover gaskets.

Scheme 1

1. Install 4 new valve cover gaskets.
2. Position the valve cover and install the 10 bolts and 4 stud bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-365420) .
4. NOTE: Apply clean engine oil to the O-ring seal prior to installation. Install the CMP sensor and the bolt. Tighten to 7 Nm (62 lb-in).
5. Connect the CMP sensor electrical connector.
6. Position the ignition coil and install the 4 bolts. Tighten to 6 Nm (53 lb-in).
7. Connect the ignition coil electrical connector.
8. Connect the spark plug wires to the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-365418) .
9. Install the engine wiring harness support bracket retainers onto the valve cover studs.
10. Connect the CHT sensor electrical connector.
11. Position back the CHT sensor boot.
12. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-365364-S14556010532010070700000) .
13. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .

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 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.

Scheme 2

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Scheme 6

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Remove the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-365412) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-365381) .
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-365364-S02729939852010070700000) .
5. NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the crankshaft in the normal direction of rotation only. 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. 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 the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the timing peg plug.
8. NOTE: The Crankshaft 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 the Crankshaft Timing Peg.
9. NOTE: The crankshaft must remain in the Top Dead Center (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. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur . Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.

Scheme 7

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Scheme 9

Scheme 10

1. Install a new diamond washer.
2. NOTE: Do not install the crankshaft pulley bolt at this time. NOTE: Apply clean engine oil on the crankshaft front seal area before installing. Install the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. 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. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. NOTE: The crankshaft must remain in the Top Dead Center (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: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool 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.
5. Remove the 6 mm x 18 mm bolt.
6. Remove the Crankshaft Timing Peg.
7. Remove the Camshaft Alignment Plate.
8. NOTE: Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft Timing Peg.
10. NOTE: Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.
11. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
12. 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.
13. Remove the Camshaft Alignment Plate.
14. Remove the 6 mm x 18 mm bolt.
15. Remove the Crankshaft Timing Peg.
16. Install the timing peg plug. Tighten to 20 Nm (177 lb-in).
17. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-365364-S02729939852010070700000) .
18. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-365381) .
19. Install the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-365412) .

Note. 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 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 tools, otherwise severe engine damage may occur.

Scheme 11

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Scheme 16

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365364-S23852065622010070700000) .
2. Compress the timing chain tensioner in the following sequence. 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 a paper clip into the hole to retain the tensioner.
3. Remove the 2 bolts and the timing chain tensioner.
4. Remove the RH timing chain guide.
5. Remove the timing chain.
6. Remove the 2 bolts and the LH timing chain guide.
7. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. The tool or the camshaft may be damaged. If necessary, remove the 2 bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

Scheme 17

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Scheme 23

1. Remove the Camshaft Alignment Plate.
2. NOTE: Do not rotate the camshafts. The valves and pistons may be damaged. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the 2 sprocket bolts.
3. If removed, install the camshaft sprockets and the 2 bolts. Do not tighten the bolts at this time.
4. Install the LH timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
5. Install the timing chain.
6. Install the RH timing chain guide. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
7. 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.
8. Using a small pick, push back and hold the ratchet mechanism.
9. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
10. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
11. 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.
12. Install the Camshaft Alignment Plate.
13. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. The tool or the camshafts may be damaged. Using the flats on the camshafts to prevent camshaft rotation, tighten the 2 bolts. Tighten to 72 Nm (53 lb-ft).
14. Install the front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365364-S23852065622010070700000) .

Scheme 24

PART NUMBER REFERENCE

1. For additional information, refer to the appropriate procedure(s).

Note. 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 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 tools, otherwise severe engine damage can occur.

Scheme 25

1. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-365364-S42620820572010070700000) .
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. NOTE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve spring retainer keys are installed, or the valve can fall into the cylinder. Remove the spark plug on the cylinder being serviced and connect the compressed air supply.
3. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. Using the 3 Valve Spring Compressors, 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.

1. NOTE: Check that there is no dirt or particles within the valve stem grooves. Check the seating of the valve collets. NOTE: Check the seating of the valve spring retainer keys. Using the 3 Valve Spring Compressors, install the valve springs. Insert the valve springs and the valve spring retainers. Using the 3 Valve Spring Compressors, compress the valve spring and install the valve spring retainer keys using some grease and a small screwdriver.
2. Disconnect the compressed air supply and install the spark plug. Tighten to 15 Nm (133 lb-in).
3. Repeat the appropriate removal and installation steps for each of the cylinders being serviced.
4. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-365364-S42620820572010070700000) .

Note. 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 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 tools, otherwise severe engine damage can occur.

Scheme 26

1. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-365364-S42620820572010070700000) .
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. NOTE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve spring retainer keys are installed, or the valve can fall into the cylinder. Remove the spark plug on the cylinder being serviced and connect the compressed air supply.
3. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. Using the 3 Valve Spring Compressors, 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.
4. Using the Valve Stem Oil Seal Remover and the Slide Hammer, remove and discard the valve seal.

Scheme 27

Scheme 28

1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install a new valve seal.
3. NOTE: Check that there is no dirt or particles within the valve stem grooves. Check the seating of the valve collets. NOTE: Check the seating of the valve spring retainer keys. Using the 3 Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Using the 3 Valve Spring Compressors, compress the valve spring and install the valve spring retainer keys using some grease and a small screwdriver.
4. Disconnect the compressed air supply and install the spark plug. Tighten to 15 Nm (133 lb-in).
5. Repeat the appropriate removal and installation steps for each of the cylinders being serviced.
6. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-365364-S42620820572010070700000) .

Removal and Installation

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.

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 . If the valve clearance has already been checked, proceed with removal.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-365364-S32561338472010070700000) .
3. 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, or the engine may be damaged. 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. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .
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 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 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 tools, otherwise severe engine damage may occur.

Scheme 29

1. Remove the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-365364-S33360651872010070700000) .
2. Remove the Camshaft Alignment Plate.
3. NOTE: Failure to follow the camshaft loosening procedure may result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference. Remove the camshafts from the engine. Loosen the 20 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 10 camshaft bearing caps. Remove the 2 camshafts.

Scheme 30

1. 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, may cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil prior to installation. Position the camshafts and bearing caps in their original location and orientation. Loosely install the 20 bolts and tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until snug. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
2. Install the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-365364-S33360651872010070700000) .

Note. 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 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 tools, otherwise severe engine damage can occur.

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-365364-S32561338472010070700000) .
3. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-365364-S17234477162010070700000) .
4. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-365422) .
5. Remove the coolant hose retainer clip, the stud bolt and the ground cable.
6. Remove the EGR tube from the cylinder head.
7. Disconnect the EGR valve electrical connector.
8. Disconnect the EGR coolant hose and remove it from the hose bracket.
9. Disconnect the coolant bypass hose.
10. Remove the cylinder block coolant drain plug.
11. Remove the 10 bolts and the cylinder head. Discard the bolts.
12. Remove and discard the head gasket.
13. 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. NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surfaces 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 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.
14. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-365375) .

Scheme 31

Scheme 32

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. 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. Use a plastic scraping tool to remove all traces of old sealant. NOTE: 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. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the locations shown in illustration.
3. Install a new cylinder head gasket.
4. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the cylinder head bolts with clean engine oil. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration, in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Tighten an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
5. Install the cylinder block coolant drain plug. Tighten to 55 Nm (41 lb-ft).
6. Connect the coolant bypass hose.
7. Connect the EGR coolant hose.
8. Connect the EGR valve electrical connector.
9. Connect the EGR tube to the cylinder head. Tighten to 55 Nm (41 lb-ft).
10. Position the ground strap and install the stud bolt to the cylinder head. Tighten to 10 Nm (89 lb-in).
11. Install the coolant hose retainer clip.
12. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-365422) .
13. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-365364-S17234477162010070700000) .
14. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-365364-S32561338472010070700000) .
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-365408) .
3. Drain the engine oil.
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch.
6. Remove and discard the oil filter.
7. Remove the 4 bolts, the oil filter adapter and discard the gasket.

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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 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.
2. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
3. Install a new oil filter.
4. NOTE: Apply thread sealant with PTFE to the EOP switch threads. Install the EOP switch. Tighten to 15 Nm (133 lb-in).
5. Connect the EOP switch electrical connector.
6. Fill the engine with clean engine oil.
7. Run the engine and check for leaks.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
4. NOTE: Apply thread sealant with PTFE to the sender threads. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-365369) .
2. Remove the oil level indicator.
3. Remove the 2 bolts and the oil level indicator tube and discard the O-ring seal. Tighten to 10 Nm (89 lb-in).
4. NOTE: Apply clean engine oil to the new O-ring seal prior to installation of the indicator tube. To install, reverse the removal procedure. Install a new O-ring seal.

Scheme 33

PART NUMBER REFERENCE

Scheme 34

PART NUMBER REFERENCE

Scheme 35

PART NUMBER REFERENCE

1. For additional information, refer to the appropriate procedure(s).

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-365364-S26238150672010070700000) .
2. Remove the 4 bolts and the oil pump screen and pickup tube. Discard the gasket.

Scheme 36

1. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep. Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
2. Install the oil pan. For additional information, refer to «OIL PAN»(ref-365364-S26238150672010070700000) .

Note. 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 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 tools, otherwise severe engine damage may occur.

Scheme 37

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365364-S23852065622010070700000) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-365364-S38782659702010070700000) .
3. Remove the oil pump chain tensioner. Release the tension on the tensioner spring. Remove the bolt and the tensioner.
4. Remove the chain from the oil pump sprocket.
5. Remove the bolt and oil pump sprocket.
6. Remove the 4 bolts and the oil pump.

Scheme 38

1. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump screen and pickup tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-365364-S38782659702010070700000) .
6. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365364-S23852065622010070700000) .

Scheme 39

PART NUMBER REFERENCE

1. For additional information, refer to the appropriate procedure(s).

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 40

1. Inspect the pilot bearing. Install a new pilot bearing as necessary.
2. Position the flywheel.
3. Using the Flywheel Locking Tool, install the 6 bolts in the sequence shown in illustration, in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
4. Install the clutch disc and the pressure plate. For additional information, refer to «CLUTCH»(ref-365423) .

1. Remove the flywheel or flexplate. For additional information, refer to «FLEXPLATE»(ref-365364-S12692107832010070700000) or «FLYWHEEL»(ref-365364-S27400835842010070700000) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-365364-S26238150672010070700000) .
3. Remove the 6 bolts and the crankshaft rear seal and retainer plate as an assembly.

Scheme 41

Scheme 42

1. Using the Crankshaft Rear Seal Installer, position the crankshaft rear seal with retainer plate onto the crankshaft.
2. Install the 6 crankshaft rear seal with retainer plate bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-365364-S26238150672010070700000) .
4. Install the flywheel or flexplate. For additional information, refer to «FLEXPLATE»(ref-365364-S12692107832010070700000) or «FLYWHEEL»(ref-365364-S27400835842010070700000) .

RH and LH engine support insulators

1. Remove the front springs. For additional information, refer to «FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)»(ref-365384) for Rear Wheel Drive (RWD) vehicles or «FRONT SUSPENSION - FOUR WHEEL DRIVE (FWD)»(ref-365383) for Four-Wheel Drive (4WD) vehicles.
2. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-365412) . RH engine support insulator
3. Remove the 3 rear pushpins and position the right inner fender splash shield aside. RH and LH engine support insulators
4. Remove the 4 RH and LH engine support insulator upper nuts.
5. Install the Lifting Eyes.
6. Raise the engine with the 3-Bar Engine Support Kit.
7. Remove the lower nut and the engine support insulator.

RH and LH engine support insulators

1. Install the engine support insulator and the engine support insulator-to-crossmember nut. Tighten to 103 Nm (76 lb-ft).
2. Lower the engine and remove the 3-Bar Engine Support Kit.
3. Remove the Lifting Eyes.
4. Install the 4 LH and RH engine support insulator-to-engine support bracket nuts. Tighten to 102 Nm (75 lb-ft). RH engine support insulator
5. Position the right inner fender splash shield and install the 3 rear pushpins. RH and LH engine support insulators
6. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-365412) .
7. Install the front springs. For additional information, refer to «FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)»(ref-365384) for RWD vehicles or «FRONT SUSPENSION - FOUR WHEEL DRIVE (FWD)»(ref-365383) for 4WD vehicles.