Engine Mechanical - 2.5L: Overhaul Mazda Tribute II

Disassembly

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, see the exploded views in this service information.

Vehicles with manual transaxles

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1. Remove the bolts, clutch pressure plate and clutch disc. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow this instruction may result in serious personal injury. CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
2. Remove the starter motor isolator.
3. Remove the bolts and the flywheel. Vehicles with automatic transaxles
4. Remove the bolts and the flexplate. All vehicles
5. Mount the engine on a suitable stand.
6. Disconnect the crankshaft position (CKP) sensor electrical connector.
7. Remove the nut and disconnect the generator electrical connections. Front wheel drive (FWD) vehicles
8. Remove the 2 lower catalytic converter bolts.
9. Remove the 6 heat shield bolts and the heat shield.
10. Remove and discard the 7 exhaust manifold nuts.
11. Remove the catalytic converter and discard the exhaust manifold gasket.
12. Remove and discard the 7 exhaust manifold studs. All vehicles
13. 13. Remove the nut, bolts and the generator.
14. Loosen the bolt and remove the accessory drive belt idler pulley.
15. Remove the 3 bolts and the accessory drive belt idler pulley and bracket.
16. Remove the bolts and the coolant pump pulley.
17. Remove the bolts and the coolant pump.
18. Detach the 2 wiring harness retainers.
19. Remove the 3 bolts and the thermostat housing assembly.
20. Remove the bolt and the oil level indicator.
21. Disconnect the engine oil pressure (EOP) switch electrical connector.
22. Remove the engine oil filter.
23. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
24. If equipped, remove the bolt and capacitor.
25. Detach the 2 wiring harness retainers.
26. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
27. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
28. Disconnect the idle air control (IAC) motor electrical connector.
29. Disconnect the swirl control valve electrical connector.
30. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
31. Disconnect the radio capacitor electrical connector.
32. Disconnect the throttle position (TP) sensor electrical connector.
33. Remove the bolts and position the intake manifold aside. NOTE: There are 2 different size bolts used. Mark the location of the bolts to make sure of installation in the correct locations.
34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
35. Remove the exhaust gas recirculation (EGR) tube.
36. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
37. Remove the nut and the radio capacitor.
38. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
39. Detach the wiring harness retainer.
40. Disconnect the EGR valve electrical connectors. Detach the wiring harness retainer.
41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
42. Detach the wiring harness retainer.
43. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
44. Disconnect the coolant hose.
45. Disconnect and remove the coolant hose.
46. Disconnect and remove the coolant hoses.
47. Remove the bolt and the KS.
48. Remove the bolts and the crankcase vent oil separator.
49. If equipped, remove the block heater.
50. Remove the crankcase vent tube and the coil-on-plugs.
51. Remove the spark plugs and the CHT sensor. Discard the CHT. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
52. Remove the bolts and the valve cover.
53. 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. CAUTION: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
54. Install the special tool in the slots on the rear of both camshafts. CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
55. Remove the engine plug bolt.
56. Install the special tool. NOTE: The special tool 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.
57. Assemble the special tools using 4 hardened washers in the locations shown in the figure.
58. Using special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard. CAUTION: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum). CAUTION: 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.
59. Using the special tool, remove the crankshaft front oil seal. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
60. Remove and discard the CKP sensor. NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
61. Remove the bolts and the engine front cover.
62. Remove the timing chain tensioner. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner. Remove the bolts and timing chain tensioner.
63. Remove the RH timing chain guide.
64. Remove the timing chain.
65. Remove the bolts and the LH timing chain guide.
66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets. CAUTION: Do not rely on the camshaft alignment plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
67. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the shoulder bolt.
68. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket. NOTE: The oil pump chain sprocket must be held in place.
69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
70. Remove the camshafts from the engine. Loosen the camshaft bearing bolts in the sequence shown in the figure, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap.
71. Remove the cylinder head. Remove and discard the cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
72. Remove the cylinder head alignment dowels.
73. Remove the bolts and the oil pan.
74. Remove the bolts and the rear crankshaft seal.
75. Remove the bolts, oil pump pickup tube and gasket.
76. Remove the bolts and the oil pump.

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Assembly

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1. Turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC). CAUTION: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
2. Remove the engine plug bolt.
3. Install the special tool. NOTE: The special tool 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.
4. Install the oil pump assembly. Tighten the bolts in the sequence shown in the figure in 2 stages. Stage 1: Tighten the bolts to 10 N.m {1.0 kgf.m, 89 in.lbf}. Stage 2: Tighten the bolts to 20 N.m {1.5 kgf.m, 177 in.lbf}. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
6. Using the special tool, install the crankshaft rear main oil seal.
7. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown in the figure. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
8. Clean and inspect all mating surfaces. CAUTION: 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.
9. Apply a 2.5 mm (0.098 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight. 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 cleaner. 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.
10. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
11. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in the figure. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
12. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
13. Clean the cylinder head-to-cylinder block mating surface 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 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. CAUTION: 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: Observe all warnings and 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.
14. Apply silicone gasket and sealant to the locations shown in the figure.
15. Install a new head gasket.
16. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the figure in 5 stages. Stage 1: Tighten the bolts to 5 N.m {0.51 kgf.m, 44 in.lbf}. Stage 2: Tighten the bolts to 15 N.m {1.5 kgf.m, 132 in.lbf}. Stage 3: Tighten the bolts to 45 N.m {4.6 kgf.m, 33 ft.lbf}. Stage 4: Turn the bolts 90 degrees. Stage 5: Turn the bolts an additional 90 degrees. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the bolts with clean engine oil prior to installation.
17. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in the figure in 3 stages. Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until finger-tight. Stage 2: Tighten the bolts to 7 N.m {0.71 kgf.m, 62 in.lbf}. Stage 3: Tighten the bolts to 16 N.m {1.6 kgf.m, 141 in.lbf}. CAUTION: 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 disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
18. Install the VCT system oil filter and the plug in the intake camshaft thrust cap. Tighten the bolts to 17 N.m {1.7 kgf.m, 150 in.lbf}.
19. Install the Variable Camshaft Timing (VCT) solenoid and the bolt. Tighten the bolts to 10 N.m {1.0 kgf.m, 89 in.lbf}.
20. Install a new crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
21. Install the oil pump chain, sprocket and bolt. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
22. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
23. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
24. Install the special tool in the slots on the rear of both camshafts. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
25. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
26. Install the LH timing chain guide and the bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
27. Install the timing chain.
28. Install the RH timing chain guide.
29. Using the edge of a vise, compress the timing chain tensioner plunger. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
30. Using a small pick, push back and hold the ratchet mechanism.
31. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
32. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
33. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
34. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 N.m {7.3 kgf.m, 53 ft.lbf}. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
35. Clean and inspect the mounting surfaces of the engine and the front cover. CAUTION: 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.
36. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
37. Install the engine front cover. Tighten* the bolts in the sequence shown in the figure, to the following specifications: Tighten the 8 mm bolts to 10 N.m {1.0 kgf.m, 89 in.lbf}. Tighten the 13 mm bolts to 48 N.m {4.9 kgf.m, 35 ft.lbf}.
38. Using the special tool, install a new crankshaft front oil seal. NOTE: Remove the throughbolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil.
39. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position. CAUTION: Do not install the crankshaft pulley bolt at this time. NOTE: Apply clean engine oil on the seal area before installing.
40. 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. CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
41. 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 N.m {10.2 kgf.m, 74 ft.lbf}. Stage 2: Tighten an additional 90 degrees (1/4 turn). CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only. CAUTION: Do not reuse the crankshaft pulley bolt.
42. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
43. Remove the special tool.
44. Remove the special tool.
45. Turn the crankshaft clockwise 1 and 3/4 turns. NOTE: Only turn the engine in the normal direction of rotation.
46. Install the special tool.
47. Turn the crankshaft clockwise until the crankshaft contacts the special tool. NOTE: Only turn the engine in the normal direction of rotation.
48. 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. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
49. Install the special tool to check the position of the camshafts. If it is not possible to install the special tool, the engine valve timing must be corrected.
50. Remove the special tool.
51. Install a new crankshaft position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
52. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 N.m {0.7 kgf.m, 62 in.lbf}.
53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
54. Remove the special tool.
55. Install the engine plug bolt. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
56. Clean the valve cover gasket surface with metal surface cleaner. Caution CAUTION: 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.
57. Apply silicone gasket and sealant to the locations shown in the figure.
58. Install the valve cover. Tighten the bolts in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
59. Install a new cylinder head temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 N.m {1.2 kgf.m, 106 in.lbf}. Tighten the spark plugs to 12 N.m {1.2 kgf.m, 106 in.lbf}. CAUTION: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.
60. Install the coil-on-plugs, bolts and the crank-case vent tube. Tighten to 8 N.m {0.8 kgf.m, 71 in.lbf}. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
61. Install the oil level indicator. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
62. If equipped, install the block heater. Tighten to 21 N.m {2.1 kgf.m, 15 ft.lbf}.
63. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
64. Install the Knock Sensor (KS) and the bolt. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}. NOTE: The KS must not touch the crankcase vent oil separator.
65. Install the 2 coolant hoses.
66. Install the coolant hose.
67. Install the coolant hose.
68. Install the EGR tube. Tighten to 55 N.m {5.5 kgf.m, 41 ft.lbf}.
69. Position the intake manifold and connect the crankcase vent oil separator tube.
70. Install the intake manifold gaskets, intake manifold and the 8 bolts. Tighten to 18 N.m {1.8 kgf.m, 159 in.lbf}.
71. Install new fuel injector O-rings. 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. CAUTION: 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.
72. Install the fuel rail with the fuel injectors and stud bolts. Tighten to 23 N.m {2.3 kgf.m, 17 ft.lbf}.
73. Install the radio capacitor and nut. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
74. Install the fuel rail insulator.
75. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
76. Connect the radio capacitor electrical connector.
77. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
78. Connect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.
79. Attach all the wiring harness retainer to the intake manifold.
80. Connect the KS and attach the 2 wiring harness retainers.
81. Connect the EGR valve electrical connector.
82. Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.
83. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
84. Attach the wiring harness retainers to the LH side valve cover stud bolts.
85. Connect the crankcase vent hose to the valve cover.
86. Attach the wiring harness retainers to the RH side valve cover stud bolts.
87. Connect the VCT electrical connector.
88. If removed, install the capacitor and bolt. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
89. Install the oil filter adapter with a new gasket. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. NOTE: Clean the gasket mating surfaces with metal surface prep. NOTE: Spin on oil filter adapter shown in the figure, element oil filter adapter similar.
90. Connect the Engine Oil Pressure (EOP) switch electrical connector.
91. Install the coolant tube retainer to the intake manifold.
92. Install the thermostat housing and bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.
93. Install the coolant pump and bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean the coolant pump mating surface with metal surface prep. NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
94. Install the 3 coolant pump pulley and bolts. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
95. Install the accessory drive belt idler pulley and bracket and the 2 bolts. Tighten to 25 N.m {2.0 kgf.m, 18 ft.lbf}.
96. Install the accessory drive belt idler pulley. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
97. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
98. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 N.m {1.7 kgf.m, 150 in.lbf}.
99. Install the new exhaust manifold gasket on the engine
100. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in the figure in 2 stages. Stage 1: Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}. Stage 2: Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak. NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
101. Install the heat shield and the 6 bolts. Tighten to Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
102. Connect the Heated Oxygen Sensor (H02S) electrical connector.
103. Install the generator, 2 nuts and 1 bolt. Tighten to Tighten to 47 N.m {4.7 kgf.m, 35 in.lbf}.
104. Connect the generator electrical connection and install the nut. Tighten to Tighten to 6 N.m {0.6 kgf.m, 53 in.lbf}.
105. Connect the generator electrical connection and attach the 2 wiring harness retainers.
106. Connect the CKP sensor electrical connector. Attach the wiring harness-to-engine retainer.
107. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand. Vehicles with automatic transaxles
108. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in the figure in 3 stages. Stage 1: Tighten to 50 N.m {5.1 kgf.m, 37 ft.lbf}. Stage 2: Tighten to 80 N.m {8.2 kgf.m, 59 ft.lbf}. Stage 3: Tighten to 112 N.m {11.4 kgf.m, 83 ft.lbf}. Vehicles with manual transaxles
109. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the figure in 3 stages. Stage 1: Tighten to 50 N.m {5.1 kgf.m, 37 ft.lbf}. Stage 2: Tighten to 80 N.m {8.2 kgf.m, 59 ft.lbf}. Stage 3: Tighten to 112 N.m {11.4 kgf.m, 83 ft.lbf}.
110. Lubricate the transaxle input shaft pilot bearing with front axle grease.
111. Using the special tool, position the clutch disc on the flywheel.
112. Position the clutch pressure plate and install the bolts. Tighten to 29 N.m {2.9 kgf.m, 21 ft.lbf} in a star pattern sequence. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Scheme 320

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations.

1. Remove the 4 bolts and the coolant outlet. Discard the gasket.
2. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve. Discard the gasket.
3. Remove and discard the cylinder head temperature (CHT) sensor. Remove the spark plugs. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plugs.

1. 5. Remove the valve tappets.
2. 6. Using the special tools, compress the valve springs and remove the valve collets, valve spring retainers and the valve springs. NOTE: Use a small screwdriver and grease to remove the valve collets.
3. 7. Inspect the components, if necessary. See «SPECIFICATIONS»(ref-348670-S01265508462009112700000) .
4. 8. Remove the valves.
5. 9. Using the special tools, remove and discard the valve seals.
6. 10. Inspect the valves. See «VALVE INSPECTION»(ref-348662-S31532068392009112700000) . Install new parts, as necessary.

1. Install the valves. NOTE: Coat the valve stems with clean engine oil.
2. Using the special tool, install the valve seals. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals. Lubricate the valve stems and guides with clean engine oil.
3. 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 collets, using grease and a small screwdriver. NOTE: Check the seating of the valve collets.
4. Install the valve tappets. NOTE: Coat the valve tappets with clean engine oil.
5. Install the spark plugs. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
6. Install a new CHT sensor. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
7. Using a new gasket, install the EGR valve and 2 bolts Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
8. Using a new gasket, install the coolant outlet and bolts. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.