Engine Mechanical - 2.0L: Other Ford Transit VII

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

Scheme 139

ITEM DESCRIPTION

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Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION - GASOLINE MODELS .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the cylinder head.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

Intake Manifold

Intake Manifold (View 1 of 3)

Scheme 141

ITEM DESCRIPTION

Intake Manifold (View 2 of 3)

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ITEM DESCRIPTION

Intake Manifold (View 3 of 3)

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ITEM DESCRIPTION

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-356770) .
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
4. Remove the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 2.0L»(ref-356780) .
5. Remove the transaxle fluid indicator.
6. Remove the intake manifold lower bolt.
7. Detach the engine wiring harness pin-type retainer from the intake manifold.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire harness retainer from the starter stud bolt.
9. Disconnect the electronic throttle control electrical connector.
10. Disconnect the fuel vapor return hose.
11. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
12. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
13. Detach the wiring harness retainer from the intake manifold and disconnect the Knock Sensor (KS) electrical connector.
14. Detach the 4 wiring harness pin-type retainers from the intake manifold.
15. Loosen the 2 intake manifold bolts.
16. Remove the 5 intake manifold bolts.
17. Remove the EGR tube from the cylinder head.
18. Disconnect the PCV hose and remove the intake manifold.

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1. Inspect and install new intake manifold gaskets if necessary.
2. Position the intake manifold and connect the PCV hose.
3. Install the EGR tube. Tighten to 55 N.m (41 lb-ft).
4. Attach the wiring harness retainer to the intake manifold and connect the KS electrical connector.
5. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
6. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 N.m (159 lb-in).
7. Attach the 4 wiring harness pin-type retainers to the intake manifold.
8. Connect the MAP sensor electrical connector.
9. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting.
10. Connect the fuel vapor return hose.
11. Connect the electronic throttle control electrical connector.
12. Connect the EOP switch electrical connector and attach the wire harness retainer to the starter stud bolt.
13. Attach the engine wiring harness pin-type retainer to the intake manifold.
14. Install the lower intake manifold bolt. Tighten to 18 N.m (159 lb-in).
15. Install the transaxle fluid indicator.
16. Install the fuel rail. For additional information, refer to «FUEL CHARGING & CONTROLS - 2.0L»(ref-356780) .
17. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
18. Install the Air Cleaner (ACL) and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-356770) .

Material

ITEM SPECIFICATION

Valve Cover (View 1 of 2)

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ITEM DESCRIPTION

Valve Cover (View 2 of 2)

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ITEM DESCRIPTION

General Equipment

GENERAL EQUIPMENT CHART

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GENERAL EQUIPMENT CHART

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ITEM DESCRIPTION

GENERAL EQUIPMENT CHART

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Cylinder Head (View 1 of 2)

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ITEM DESCRIPTION

Cylinder Head (View 2 of 2)

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ITEM DESCRIPTION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-356758) .
3. Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in). NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.19 in).
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
5. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
6. Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
7. Remove the 2 bellhousing-to-oil pan bolts.
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Slide the transaxle rearward 5 mm (0.19 in).
10. Remove the 2 bolts and the accessory drive belt splash shield.
11. Drain the engine oil. Install the drain plug. Tighten to 28 N.m (21 lb-ft).
12. Remove the 4 engine front cover-to-oil pan bolts.
13. Remove the 13 bolts and the oil pan.

Scheme 157

1. Clean and inspect all mating surfaces. 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 traces of sealant.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
3. Position the oil pan onto the engine and install the 13 oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Tighten to 10 N.m (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown in illustration. Tighten to 25 N.m (18 lb-ft).
6. Install the accessory drive belt splash shield and the 2 bolts. Tighten to 9 N.m (80 lb-in).
7. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing lower bolts to slide the transaxle and engine together. Tighten to 48 N.m (35 lb-ft).
8. Tighten the remaining LH bellhousing-to-engine bolt and the remaining rear engine-to-bellhousing stud bolt. Tighten to 48 N.m (35 lb-ft).
9. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 N.m (35 lb-ft).
10. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 N.m (35 lb-ft).
11. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
12. Tighten the top bellhousing-to-engine bolt and stud bolt. Tighten to 48 N.m (35 lb-ft).
13. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-356758) .
14. Fill the engine with clean engine oil.

ITEM SPECIFICATION

Scheme 158

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-356734-S33031445032010022700000) .
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
4. Drain the engine oil, then install the drain plug. To install, tighten to 28 N.m (21 lb-ft).
5. Remove the 2 oil pan-to-bellhousing bolts.
6. Remove the 2 bellhousing-to-oil pan bolts.
7. Remove the 13 bolts and the oil pan.
8. Remove the 2 bolts and the oil pump screen and pickup tube. NOTE: Discard the gasket and clean and inspect the gasket mating surfaces.
9. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
10. Remove the chain from the oil pump sprocket.
11. Remove the bolt and oil pump sprocket.
12. Remove the 4 bolts and the oil pump.

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1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages: NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep. Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten to 20 N.m (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 N.m (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 N.m (89 lb-in).
5. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 N.m (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 N.m (89 lb-in).
7. Clean all mating surfaces with metal surface prep. 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 traces to sealant.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 N.m (18 lb-ft).
11. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 N.m (35 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 N.m (35 lb-ft).
13. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
14. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-356734-S33031445032010022700000) .
15. Fill the engine with clean engine oil.

ITEM SPECIFICATION

Scheme 164

ITEM DESCRIPTION

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1. Remove the oil level indicator.
2. Remove the oil level indicator tube bolt. To install, tighten to 10 N.m (89 lb-in).
3. Detach the wiring harness retainer from the oil level indicator tube.
4. Remove the oil level indicator tube and discard the O-ring seal. To install, lubricate the new O-ring seal with clean engine oil.
5. To install, reverse the removal procedure.

ITEM SPECIFICATION

ITEM SPECIFICATION

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

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

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

Note. For additional information, refer to the exploded view under the Assembly procedure.

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1. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
2. Mount the engine on a suitable engine stand.
3. Loosen the bolt and remove the accessory drivebelt idler pulley.
4. Remove the 3 bolts and the coolant pump pulley.
5. Remove the 3 bolts and the coolant pump.
6. Disconnect the oil cooler hose and lower radiator hose from the thermostat housing.
7. Disconnect the EGR valve coolant hose.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
9. Disconnect the oil cooler hoses.
10. Remove the bolt and the oil cooler. Discard the oil cooler.
11. Remove the oil filter, 4 bolts and the oil filter adapter. Discard the oil filter and gasket.
12. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
13. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
14. Detach the generator wiring harness retainer from the valve cover stud.
15. Disconnect the 4 fuel injector electrical connectors and detach the 5 wiring harness retainers from valve cover stud bolts and intake manifold.
16. Remove the 2 bolts and the fuel rail with the fuel injectors.
17. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
18. Disconnect the throttle control electrical connector.
19. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. Detach the 3 wiring harness retainers from the intake manifold.
20. Disconnect the EGR valve electrical connector.
21. Remove the lower intake manifold bolt.
22. Remove the bolt and the oil level indicator tube. Discard the O-ring seal.
23. Loosen the 2 intake manifold bolts. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
24. Remove the 5 intake manifold bolts.
25. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. 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. Remove the intake manifold.
26. Remove the EGR tube.
27. Remove the radio interference capacitor bracket bolt and position the bracket aside.
28. Disconnect the coolant bypass hose.
29. Remove the 4 bolts and the coolant outlet.
30. Disconnect the coolant bypass hose.
31. Remove the 3 bolts, thermostat housing and thermostat.
32. Remove the 2 bolts, stud bolt and the A/C compressor.
33. Remove the bolt and the KS.
34. Remove the 8 bolts and the crankcase vent oil separator.
35. Remove the 3 bolts and the intermediate shaft bracket.
36. Remove the 4 bolts and the ignition coil-on-plugs.
37. Remove the spark plugs and the CHT sensor. NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
38. Remove the bolts and the valve cover.
39. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. The hole in the crankshaft pulley should be in the 6 o'clock position.
40. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
41. Remove the engine plug bolt.
42. Install the Crankshaft TDC Timing Peg. 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.
43. 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.
44. Using the Oil Seal Remover, remove the crankshaft front seal. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
45. Remove the 2 bolts and the CKP sensor.
46. Remove the 22 bolts and the engine front cover.
47. 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.
48. Remove the 2 bolts and the timing chain tensioner.
49. Remove the RH timing chain guide.
50. Remove the timing chain.
51. Remove the 2 bolts and the LH timing chain guide.
52. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
53. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
54. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
55. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
56. Remove the camshafts from the engine.
57. Remove the valve tappets. 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.
58. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) . 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.
59. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
60. Remove the cylinder head alignment dowels.
61. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
62. 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-356743) .
63. Remove the 13 bolts and the oil pan.
64. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
65. Remove the 2 bolts, oil pump pickup tube and gasket. Discard the gasket.
66. Remove the 4 bolts and the oil pump.
67. Remove the Crankshaft TDC Timing Peg.
68. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
69. Remove the connecting rod cap bolts and cap. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
70. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
71. Remove the bolts in the sequence shown in illustration. Remove the main bearing beam. Discard the bolts.
72. Remove the crankshaft from the engine block.
73. Remove the main bearings from the main bearing beam. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
74. Remove the main bearings from the cylinder block.
75. Remove the 4 oil squirters.
76. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .

ITEM SPECIFICATION

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GENERAL EQUIPMENT CHART

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Lower Engine Block (View 1)

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Lower Engine Block (View 2)

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Front Engine Block

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Cylinder Head

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ITEM DESCRIPTION

Intake Manifold

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ITEM DESCRIPTION

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. All parts must be thoroughly cleaned and 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. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, to ENGINE SYSTEM-GENERAL INFORMATION .

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1. Install the 4 oil squirters.
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 25 N.m (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block housing main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 N.m (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 25 N.m (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.
20. Install the connecting rod caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 N.m (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
21. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
22. Install the Crankshaft TDC Timing Peg. 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 until the timing drive components and crankshaft pulley are installed.
23. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep. Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten to 20 N.m (177 lb-in).
24. Using a new oil pump pickup tube gasket, install the pickup tube and bolts. Tighten to 10 N.m (89 lb-in).
25. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.
26. Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown in illustration. Tighten to 10 N.m (89 lb-in).
27. Clean and inspect all mating surfaces. 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 traces of sealant.
28. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with 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.
29. Install the oil pan. Install the 2 oil pan bolts finger-tight.
30. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
31. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 N.m (18 lb-ft).
32. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
33. Apply silicone gasket and sealant to the locations shown in illustration.
34. Install a new cylinder head gasket.
35. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 15 N.m (133 lb-in). Stage 3: Tighten to 45 N.m (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
36. Install the valve tappets. NOTE: If the camshafts and valve tappets are to be reused, make sure they are assembled in their original positions. NOTE: Coat the valve tappets with clean engine oil.
37. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten one turn at a time until tight. Stage 2: Tighten to 7 N.m (62 lb-in). Stage 3: Tighten to 16 N.m (142 lb-in).
38. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket. The crankshaft sprocket flange must be facing away from the engine block.
39. Install the oil pump chain, sprocket and bolt. Tighten to 25 N.m (18 lb-ft).
40. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 N.m (89 lb-in).
41. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 N.m (89 lb-in).
42. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
43. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
44. Install the LH timing chain guide and the 2 bolts. Tighten to 10 N.m (89 lb-in).
45. Install the timing chain.
46. Install the RH timing chain guide. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
47. Using the edge of a vise, compress the timing chain tensioner plunger. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
48. Using a small pick, push back and hold the ratchet mechanism.
49. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
50. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
51. Install the timing chain tensioner and the 2 bolts. Tighten to 10 N.m (89 lb-in). Remove the paper clip to release the piston.
52. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 N.m (53 lb-ft). NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
53. Clean and inspect the mounting surfaces of the engine and the front cover. 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.
54. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
55. Install the engine front cover. Tighten the 22 bolts in the sequence shown in illustration to the following specifications: Tighten the 8-mm bolts to 10 N.m (89 lb-in). Tighten the 13-mm bolts to 48 N.m (35 lb-ft).
56. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
57. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
58. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
59. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 N.m (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
60. Remove the 6 mm x 18 mm bolt.
61. Remove the Crankshaft TDC Timing Peg.
62. Remove the Camshaft Alignment Plate.
63. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. NOTE: Only turn the engine in the normal direction of rotation.
64. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. NOTE: Only hand-tighten the bolt or damage to the front cover can occur. If it is not possible to install the bolt, the engine valve timing must be corrected.
65. 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.
66. Remove the Camshaft Alignment Plate.
67. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
68. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 N.m (62 lb-in).
69. Remove the 6 mm x 18 mm bolt.
70. Remove the Crankshaft TDC Timing Peg.
71. Install the engine plug bolt. Tighten to 20 N.m (177 lb-in).
72. Clean the valve cover gasket surface with metal surface prep. 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.
73. Apply silicone gasket and sealant to the locations shown in illustration.
74. Install the valve cover. Tighten the 14 bolts in the sequence shown in illustration to 10 N.m (89 lb-in).
75. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs. NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug. Tighten the CHT sensor to 12 N.m (106 lb-in). Tighten the spark plugs to 12 N.m (106 lb-in).
76. Install the 4 ignition coil-on-plugs and the 4 bolts. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots. Tighten to 10 N.m (89 lb-in).
77. Install the intermediate shaft bracket and the 3 bolts. Tighten to 48 N.m (35 lb-ft).
78. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 N.m (89 lb-in).
79. Install the KS and the bolt. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator. Tighten to 20 N.m (177 lb-in).
80. Install the A/C compressor, 2 bolts and the stud bolt. Tighten to 25 N.m (18 lb-ft).
81. Install the thermostat housing and 3 bolts. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary. Tighten to 10 N.m (89 lb-in).
82. Connect the coolant bypass hose.
83. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 N.m (89 lb-in).
84. Connect the coolant bypass hose.
85. Install the radio interference capacitor bracket and bolt. Tighten to 10 N.m (89 lb-in).
86. Install the EGR tube. Tighten to 55 N.m (41 lb-ft).
87. Inspect and install new intake manifold gaskets if necessary.
88. Position the intake manifold and connect the PCV hose. 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.
89. Install the intake manifold and hand-tighten the 2 intake manifold bolts. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
90. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 N.m (159 lb-in).
91. Using a new O-ring seal, install the oil level indicator tube assembly and the bolt. NOTE: Lubricate the new O-ring with clean engine oil. Tighten to 10 N.m (89 lb-in).
92. Install the lower intake manifold bolt. Tighten to 18 N.m (159 lb-in).
93. Connect the EGR valve electrical connector.
94. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector. Attach the 3 wiring harness retainers to the intake manifold.
95. Connect the throttle control electrical connector.
96. Connect the KS electrical connector and pin-type retainer.
97. Install new fuel injector O-rings. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
98. Install the fuel rail with the fuel injectors and the 2 bolts. Tighten to 25 N.m (18 lb-ft).
99. Connect the 4 fuel injector electrical connectors and attach the 4 wiring harness retainers to valve cover stud bolts and intake manifold.
100. Attach the wiring harness retainer on the valve cover stud.
101. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
102. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
103. Using a new gasket, install the oil filter adapter and the 4 bolts. NOTE: Clean the gasket mating surfaces with metal surface prep.
104. Install a new oil cooler and bolt. NOTE: A new oil cooler must be installed or severe damage to the engine can occur. Tighten to 34 N.m (25 lb-ft).
105. Install the oil filter. NOTE: Lubricate the oil filter gasket with clean engine with clean engine oil prior to installation. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
106. Connect the oil cooler hoses.
107. Connect the Engine Oil Pressure (EOP) switch electrical connector.
108. Connect the EGR valve coolant hose.
109. Connect the oil cooler hose and lower radiator hose to the thermostat housing.
110. Position the coolant pump and install the 3 bolts. Tighten to 10 N.m (89 lb-in).
111. Install the coolant pump pulley and 3 bolts. Tighten to 20 N.m (177 lb-in).
112. Install the accessory drive belt idler pulley. Tighten to 25 N.m (18 lb-ft).
113. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
114. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in illustration in 3 stages

1. Stage 1: Tighten to 50 N.m (37 lb-ft).
2. Stage 2: Tighten to 80 N.m (50 lb-ft).
3. Stage 3: Tighten to 112 N.m (83 lb-ft).

Scheme 258

ITEM SPECIFICATION

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

1. Check the installation depth of the torque converter. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease. Lay a straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 bellhousing-to-engine fasteners. Tighten to 48 N.m (35 lb-ft).
3. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
4. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
5. Install the 4 torque converter nuts. NOTE: If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal. Tighten to 35 N.m (26 lb-ft).
6. Install the starter motor isolator.
7. Install the starter motor, stud bolt and the bolt. Install the upper bolt and lower stud bolt finger-tight. Tighten the upper bolt to 35 N.m (26 lb-ft). Tighten the lower stud bolt to 35 N.m (26 lb-ft).
8. Connect the starter motor electrical terminals and install the 2 nuts. Tighten the small nut to 5 N.m (44 lb-in). Tighten the large nut to 12 N.m (106 lb-in).
9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
10. Install the power steering tube bracket on the A/C compressor stud bolt and install the nut. Tighten to 20 N.m (177 lb-in).
11. Install the engine ground wire and the bolt. Tighten to 48 N.m (35 lb-ft).
12. Install the power steering tube bracket on the starter motor stud bolt and install the nut. Tighten to 20 N.m (177 lb-in).
13. Attach the starter wire harness retainer to the starter motor stud bolt.
14. Connect the Crankshaft Position (CKP) sensor electrical connector.
15. Attach the 2 CKP sensor wire harness retainers.
16. Attach the wire harness pin-type retainer to the intake manifold.
17. Connect the Power Steering Pressure (PSP) switch electrical connector.
18. Connect the A/C compressor electrical connector.
19. Connect the 2 transaxle electrical connectors.
20. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
21. Connect the Output Shaft Speed (OSS) sensor electrical connector.
22. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut. Tighten to 25 N.m (18 lb-ft).
23. Install the nut for the HO2S and CMS wire connector bracket. Tighten to 25 N.m (18 lb-ft).
24. Using the lift table, position the engine and transaxle assembly in the vehicle.
25. Install the transaxle mount plate and the 5 nuts. Tighten the center nut to 150 N.m (111 lb-ft). Tighten the 4 outer nuts to 48 N.m (35 lb-ft).
26. Install the engine mount and the 3 bolts. Tighten to 48 N.m (35 lb-ft).
27. Install the 2 motor mount nuts. Tighten to 90 N.m (66 lb-ft).
28. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 N.m (35 lb-ft).
29. Install the 2 lower bellhousing-to-oil pan bolts. Tighten to 48 N.m (35 lb-ft).
30. Install the transaxle roll restrictor and the 2 bolts. NOTE: The bolts are different lengths, make sure the bolts are in the correct location. Install the transaxle roll restrictor. Install the short bolt. Install the long bolt. Tighten to 70 N.m (52 lb-ft).
31. Install the transaxle fluid indicator.
32. Connect the heater hose to the coolant tube.
33. Connect the upper radiator hose and the heater hose to the coolant bypass.
34. Connect the coolant degas bottle vent hose to the coolant bypass.
35. Connect the coolant degas bottle hose and install the retaining clip.
36. Install the power steering pump. For additional information, to «POWER STEERING»(ref-356771) .
37. Clean and inspect the exhaust manifold flange. For additional information, to Exhaust Manifold Cleaning and Inspection in «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
38. Install the exhaust manifold. For additional information, to «EXHAUST MANIFOLD»(ref-356734-S41703644142010022700000) .
39. Connect the power steering cooler tube.
40. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt. Tighten to 18 N.m (159 lb-in).
41. Install the power steering tube clip and the bolt. Tighten to 10 N.m (89 lb-in).
42. Install the LH and RH halfshafts. For additional information, to «FRONT DRIVE HALFSHAFTS»(ref-356762) .
43. Install a new engine oil filter. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
44. Connect the lower radiator hose to the radiator.
45. Install the cooling fan motor and shroud. For additional information, to «ENGINE COOLING»(ref-356777) .
46. Using 2 new O-ring seals, connect the A/C tubes to the compressor.
47. Install the 2 A/C tube-to-compressor nuts. Tighten to 15 N.m (133 lb-in).
48. Position and attach the 2 B+ battery cable wire harness retainers.
49. Install the generator. For additional information, to «CHARGING SYSTEM»(ref-356745) .
50. Install the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
51. Install the 2 front wheels and tires. For additional information, refer to «WHEELS & TIRES»(ref-356740) .
52. Install the engine oil level indicator.
53. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.
54. Install the secondary latches.
55. Connect the transaxle shift cable to the lever and bracket.
56. Connect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and attach the wire harness retainer.
57. Connect the starter wire harness electrical connector.
58. Connect the 3 PCM electrical connectors.
59. Install the ground wire and nut on the negative battery terminal. Tighten to 10 N.m (89 lb-in).
60. Attach the engine harness to the coolant outlet bracket harness retainer.
61. Connect and attach the 2 engine harness electrical connectors.
62. Install the power brake booster vacuum tube into the quick connect fitting.
63. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-356782) .
64. Connect the fuel tube quick connect coupling to the fuel tube near the bulkhead. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-356782) .
65. Install the negative battery cable ground and the bolt. Tighten to 10 N.m (89 lb-in).
66. Attach the 3 positive battery cable wire harness retainer.
67. Connect the positive battery cable nut. Tighten to 10 N.m (89 lb-in).
68. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-356758) .
69. Connect the crankcase vent tube to the valve cover.
70. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-356770) .
71. Fill the engine with clean engine oil.
72. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
73. Evacuate and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
74. Install the splash shield, pin-type retainer and the 2 bolts.