Engine Mechanical - 2.5L: Removal & Installation Mazda Tribute II

ACCESSORY DRIVE BELT TENSIONER REMOVAL/INSTALLATION - 2.5L

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the pin-type retainer, 5 bolts and the RH splash shield. To install, tighten to 9 N.m {0.9 kgf.m, 80 in.lbf}. NOTE: The accessory drive belt tensioner must be replaced as a complete unit.
3. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the water pump pulley and remove the accessory drive belt from the pulley.
4. Remove the 2 bolts and the accessory drive belt tensioner. To install, tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. NOTE: The accessory drive belt tensioner must be replaced as a complete unit.
5. To install, reverse the removal procedure.

Removal/Installation

All idler pulleys

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the pin-type retainer, 5 bolts and the RH splash shield. To install, tighten to 9 N.m {0.9 kgf.m, 80 in.lbf}.
3. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the idler pulley. Smooth idler pulley
4. Loosen the bolt and remove the smooth accessory drive belt idler pulley. To install, tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Grooved idler pulleys
5. Remove the 3 bolts and the grooved accessory drive belt idler pulley and bracket. To install, tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
6. To install, reverse the removal procedure.

VALVE COVER REMOVAL/INSTALLATION - 2.5L

Valve Cover (View 1 of 2)

Scheme 17

Valve Cover (View 2 of 2)

Scheme 18

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG REMOVAL/INSTALLATION - 2.5L»(ref-348659-S03372976482009112700000) .
3. Disconnect the crankcase vent hose from the valve cover.
4. Remove the 4 engine cover studs.
5. Detach the 3 wire harness retainers from the valve cover stud bolts.
6. Disconnect the camshaft position (CMP) sensor electrical connector.
7. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
8. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
9. Remove the oil level indicator.
10. Remove the 14 valve cover retainers, the valve cover and the gasket.

Installation

Clean and inspect the sealing surfaces.

Scheme 19

Scheme 20

1. 2. Apply silicone gasket and sealant to the locations shown in the figure. 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 prep.
2. 3. Install the valve cover, gasket and retainers. Tighten in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean and inspect the gasket. Install a new gasket, if necessary.
3. 4. Install the oil level indicator.
4. 5. Connect the VCT solenoid electrical connector.
5. 6. Connect the CHT sensor electrical connector.
6. 7. Connect the CMP sensor electrical connector.
7. 8. Attach the 3 wire harness retainers to the valve cover stud bolts.
8. 9. Install the 4 engine cover studs.
9. 10. Connect the crankcase vent hose to the valve cover.
10. 11. Install the ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG REMOVAL/INSTALLATION - 2.5L»(ref-348659-S03372976482009112700000) .

Scheme 21

1. For additional information, see the procedures in this service information.

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1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Disconnect the battery ground cable.
3. Remove the degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - 2.5L»(ref-348664-S29854818072009112700000) .
4. Remove the valve cover. See «VALVE COVER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S40774904912009112700000) .
5. Remove the front RF wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-348652-S29323856712009112700000) .
6. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .
7. Using the crankshaft pulley bolt, turn the crankshaft sprocket 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 top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
8. Install the special tool in the slots on the rear of both camshafts. CAUTION: The Camshaft Alignment Plate 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.
9. Remove the engine bolt plug.
10. Install the crankshaft timing peg and turn the crankshaft clockwise until the crankshaft contacts the crankshaft timing peg. 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 the camshaft removal and installation.
11. Install a standard 6 mm bolt (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 bolt or damage to the front cover can occur.
12. Remove the front cover timing hole plug from the engine front cover.
13. Remove the upper front cover timing hole plug from the engine front cover.
14. Reposition the special tool to the slot on the rear of the intake camshaft only.
15. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position. NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an M6 x 18mm (1.18 in) bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear.
16. Remove the special tool.
17. Using the flats of the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
18. Remove the timing chain from the camshaft phaser and sprocket.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one at a time until all tension is released from the camshaft bearing caps. Remove the bolts and 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.
21. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

Scheme 36

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Scheme 39

1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 N.m {7.2 kgf.m, 53 ft.lbf}. NOTE: If new parts are installed, transfer the reference marks made during disassembly to the new parts.
2. Install the camshafts and bearing caps in their original location and orientation. Tighten the bolts in the sequence shown in the figure in 3 stages. Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 N.m {0.7 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 removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
3. Install the special tool.
4. Install the timing chain on the camshaft phaser and sprocket.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm. NOTE: Releasing the tensioner arm will remove the slack from the timing chain release.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the bolts. Tighten to 72 N.m {7.3 kgf.m, 53 ft.lbf}. NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
8. Remove the special tool.
9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
10. Remove the special tool.
11. Install the upper front cover timing hole plug. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug. Install the plug and tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
13. Install the engine plug bolt. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
14. Install the accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .
15. Install the front RF wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-348652-S29323856712009112700000) .
16. Install the valve cover. See «VALVE COVER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S40774904912009112700000) .
17. Install the degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - 2.5L»(ref-348664-S29854818072009112700000) .
18. Connect the battery ground cable.

VALVE TAPPETS REMOVAL/INSTALLATION - 2.5L

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the camshafts. See «CAMSHAFTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S30368809762009112700000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S04185467092009112700000) . CAUTION: 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 locations. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number of 0.650 has the thickness of 3.650 mm.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

Scheme 40

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000)
2. Remove the camshafts. See «CAMSHAFTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S30368809762009112700000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S04185467092009112700000) . NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
4. Remove the spark plugs. See «SPARK PLUGS REMOVAL/INSTALLATION - 2.5L»(ref-348659-S17051964762009112700000) .
5. Connect the compressed air supply to the No. 1 cylinder. CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed.
6. Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring. NOTE: Place all parts in order to one side.

1. Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver. NOTE: Check the seating of the valve collet.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all the cylinders.
4. Install the spark plugs. See «SPARK PLUGS REMOVAL/INSTALLATION - 2.5L»(ref-348659-S17051964762009112700000) .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. See «CAMSHAFTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S30368809762009112700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the camshafts. See «CAMSHAFTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S30368809762009112700000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S04185467092009112700000) . NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
4. Remove the spark plugs. See «SPARK PLUGS REMOVAL/INSTALLATION - 2.5L»(ref-348659-S17051964762009112700000) .
5. Connect the compressed air supply to the No. 1 cylinder. CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed.
6. Apply compressed air to the cylinder and remove the valve spring. Using the special tools, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring. NOTE: Place all parts in order to one side.
7. Using the special tool, remove and discard the valve seal.

Scheme 41

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Scheme 43

1. Install the valve stem seal installation sleeve.
2. Using the special tool, install the valve seal.
3. Using the special tools, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver. NOTE: Check the seating of the valve collet.
4. Disconnect the compressed air supply and install the spark plug.
5. Install the spark plugs. See «SPARK PLUGS REMOVAL/INSTALLATION - 2.5L»(ref-348659-S17051964762009112700000) .
6. Repeat the appropriate removal and installation steps for all of the other cylinders.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. See «CAMSHAFTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S30368809762009112700000) .

Scheme 44

Scheme 45

1. For additional information, see the procedures in this service information.

Scheme 46

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the front RH wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-348652-S29323856712009112700000) .
3. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .
4. Remove the valve cover. See «VALVE COVER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S40774904912009112700000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC). The hole on the crankshaft pulley should be in the 6 o'clock position. CAUTION: 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.
6. Install the special tool in the slots on the rear of both camshafts. CAUTION: 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
7. Remove the engine plug bolt.
8. 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 in the TDC position during the crankshaft pulley removal and installation.
9. 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. 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.

Scheme 47

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1. Install a new diamond washer.
2. 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.
3. 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.
4. 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 {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.
5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
6. Remove the special tool.
7. Remove the special tool.
8. Turn the crankshaft 1-3/4 turns. NOTE: Only turn the engine in the normal direction of rotation.
9. Install the special tool.
10. Turn the crankshaft clockwise until the crankshaft contacts the special tool. NOTE: Only turn the engine in the normal direction of rotation.
11. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
12. 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 by repeating this procedure.
13. Remove the special tool.
14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
15. Remove the special tool.
16. Install the engine plug bolt. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
17. Install the accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .
18. Install the front RH wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-348652-S29323856712009112700000) .
19. Install the valve cover. See «VALVE COVER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S40774904912009112700000) .

Scheme 54

1. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.5L»(ref-348658-S13756073842009112700000) .
2. 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.

Scheme 55

1. Using the special tool, install the crankshaft front oil seal. NOTE: Remove the through bolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil.
2. Install the crankshaft pulley. See «CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.5L»(ref-348658-S13756073842009112700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. If equipped, remove the automatic transaxle. See «TRANSAXLE INSTALLATION»(ref-348671-S35343071702009112700000) .
3. Remove the 6 bolts and the flexplate.

Scheme 56

1. Install the flexplate and 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}. NOTE: Special bolts are used for installation. Do not use standard bolts.
2. Install the automatic transaxle. See «ENGINE REMOVAL - AUTOMATIC TRANSAXLE»(ref-348658-S27209337832009112700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the manual transaxle and clutch. See «ENGINE INSTALLATION - MANUAL TRANSAXLE»(ref-348658-S13211233092009112700000) .
3. Remove the 6 bolts and the flywheel.

1. Install the flywheel and 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}. NOTE: Special bolts are used for installation. Do not use standard bolts.
2. Install the manual transaxle and clutch. See «TRANSAXLE INSTALLATION»(ref-348671-S35343071702009112700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the flexplate or flywheel. See «FLEXPLATE REMOVAL/INSTALLATION - 2.5L»(ref-348658-S08147945602009112700000) or «FLYWHEEL REMOVAL/INSTALLATION - 2.5L»(ref-348658-S20944372132009112700000) .
3. Drain the engine oil. Install the drain plug and. Tighten to 28 N.m {2.8 kgf.m, 21 ft.lbf}.
4. Remove the 17 bolts and the oil pan. CAUTION: If the oil pan is not removed damage to the rear oil seal retainer joint can occur. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

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Scheme 61

1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear oil seal with retainer plate and bolts. Tighten the bolts in the sequence shown in the figure to 10 N.m {1.0 kgf.m, 89 in.lbf}.
3. Clean and inspect all the oil pan and cylinder block 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.
4. 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.
5. Install the 4 bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in the figure to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
7. Install the flexplate or flywheel. See «FLEXPLATE REMOVAL/INSTALLATION - 2.5L»(ref-348658-S08147945602009112700000) or «FLYWHEEL REMOVAL/INSTALLATION - 2.5L»(ref-348658-S20944372132009112700000) .
8. Fill the engine with clean engine oil.

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Scheme 63

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the accessory drive belt and idler pulleys. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) and «ACCESSORY DRIVE BELT TENSIONER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S01902654092009112700000) .
3. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.5L»(ref-348658-S13756073842009112700000) .
4. Remove the engine mount. See «ENGINE MOUNT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S07754717492009112700000) .
5. 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.
6. Remove the 3 bolts and the coolant pump pulley.
7. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove and the 2 bolts and the CKP sensor.
10. Remove the bolts and the engine front cover.

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1. 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.
2. 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.
3. 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}.
4. Install the accessory drive belt idler pulley and bracket and the 3 bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
5. Install the water pump pulley and bolts. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
6. Using the special tool, install the crankshaft front oil seal. NOTE: Remove the through-bolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil.
7. Install the engine mount. See «ENGINE MOUNT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S07754717492009112700000) .
8. Install the crankshaft pulley. See «CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.5L»(ref-348658-S13756073842009112700000) .
9. 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 bolt or damage to the front cover can occur.
10. Install a new CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
11. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 N.m {0.7 kgf.m, 62 in.lbf}.
12. Connect the CKP sensor electrical connector.
13. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
14. Install the accessory drive belt and idler pulleys. See «ACCESSORY DRIVE BELT TENSIONER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S01902654092009112700000) and «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .

Scheme 69

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Scheme 74

1. With vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Remove the engine front cover. See «TIMING DRIVE COMPONENTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S42791857782009112700000) .
3. 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.
4. Remove the timing chain tensioner arm.
5. Remove the timing chain.
6. Remove the 2 bolts and the timing chain guide.
7. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket. CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket. CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Scheme 75

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Scheme 77

Scheme 78

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the timing chain guide and the 2 bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
3. Install the timing chain.
4. Install the timing chain tensioner arm.
5. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
6. Using the flats on the camshaft 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.
7. Install the engine front cover. See «TIMING DRIVE COMPONENTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S42791857782009112700000) .

Scheme 79

Scheme 80

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Install the special tool.
3. Remove the engine mount bracket bolt. To install, tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
4. Use the special tool to raise the engine 25 mm (9.98 in).
5. Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
6. Remove the 3 bolts and the engine mount. To install, tighten to 55 N.m {5.6 kgf.m, 41 ft.lbf}.
7. To install, reverse the removal procedure.

Scheme 81

Scheme 82

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Release the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-348657-S11437714852009112700000) .
3. Drain the engine coolant. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .
4. Remove the timing drive components. See «TIMING DRIVE COMPONENTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S42791857782009112700000) .
5. Remove the special tool.
6. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
7. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the bearing cap bolts. Remove the bolts and 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.
8. 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.
9. Inspect the valve tappets. See «VALVE TAPPET INSPECTION - 2.5L»(ref-348662-S35820008322009112700000) .
10. Remove the intake manifold. See «INTAKE MANIFOLD REMOVAL/INSTALLATION - 2.5L»(ref-348655-S27678094552009112700000) .
11. Remove the generator. See «GENERATOR REMOVAL/INSTALLATION - 2.5L»(ref-348661-S19802446892009112700000) .
12. Remove the catalytic converter exhaust manifold. See «CATALYTIC CONVERTER AND EXHAUST MANIFOLD REMOVAL/INSTALLATION - 2.5L»(ref-348629-S27133143182009112700000) .
13. Disconnect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose from the engine coolant outlet and the EGR valve.
14. Remove the bolts and the cylinder head.

1. Discard the bolts and the cylinder head gasket.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. 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 silicon or gasket material with a plastic scraper. Apply silicon gasket remover, following package directions, and allow to set for several minutes. Remove silicone gasket remover with a plastic scraper. A second application of silicon gasket remover may be required if residual traces of silicon 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 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.
2. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. See «CYLINDER HEAD DISTORTION CHECK»(ref-348662-S09088357192009112700000) .
3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
4. Apply silicone gasket and sealant to the locations shown in the figure.
5. Install a new head gasket.
6. 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 {0.5 kgf.m, 44 in.lbf}. Stage 2: Tighten the bolts to 15 N.m {1.5 kgf.m, 97 in.lbf}. Stage 3: Tighten the bolts to 45 N.m {4.5 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.
7. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
8. Connect the EGR coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Install the catalytic converter and exhaust manifold. See «CATALYTIC CONVERTER AND EXHAUST MANIFOLD REMOVAL/INSTALLATION - 2.5L»(ref-348629-S27133143182009112700000) .
11. Install the generator. See «GENERATOR REMOVAL/INSTALLATION - 2.5L»(ref-348661-S19802446892009112700000) .
12. Install the intake manifold. See «INTAKE MANIFOLD REMOVAL/INSTALLATION - 2.5L»(ref-348655-S27678094552009112700000) .
13. Install the valve tappets in their original positions. NOTE: Lubricate the valve tappets with clean engine oil.
14. Install the camshaft 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 cap bolts, one turn at a time, until finger tight. Stage 2: Tighten to 7 N.m {0.7 kgf.m, 62 in.lbf}. Stage 3: Tighten to 16 N.m {1.6 kgf.m, 142 in.lbf}. CAUTION: Install the camshafts with the alignment notches in the camshafts lined up so the camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Failure to follow this procedure can cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
15. Install the special tool.
16. Install the timing drive components. See «TIMING DRIVE COMPONENTS REMOVAL/INSTALLATION - 2.5L»(ref-348658-S42791857782009112700000) .
17. Fill and bleed the engine cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .

ENGINE REMOVAL - MANUAL TRANSAXLE

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1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. Release the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-348657-S11437714852009112700000) .
3. Remove the engine air cleaner and air cleaner outlet pipe. See «AIR CLEANER REMOVAL/INSTALLATION - 3.0L»(ref-348656-S06903233342009112700000) .
4. Remove the battery tray. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) .
5. Drain the engine oil. Install the drain plug. To install, tighten to 28 N.m {2.8 kgf.m, 21 ft.lbf}.
6. Remove the LH halfshaft and the intermediate shaft.
7. Drain the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .
8. Remove the bolts and the lateral support crossmember.
9. Remove the exhaust downpipe and exhaust intermediate pipe. See «EXHAUST INTERMEDIATE PIPE REMOVAL/INSTALLATION»(ref-348629-S02664189312009112700000) .
10. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) .
11. Press the locking tab to release the generator air duct and remove.
12. If equipped, remove the bolt and ground eyelet.
13. Remove the power distribution box (PDB) cover.
14. Remove the nut and cable from the PDB.
15. Disconnect the electrical connector from the PDB.
16. Remove the bolt and ground strap.
17. Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.
18. Position the clutch hydraulic line aside. Remove the clutch hydraulic line bracket-to-transaxle bolt. Disconnect the clutch hydraulic line from the clutch slave cylinder. Plug the hydraulic line. Position the clutch hydraulic line aside.
19. Disconnect the vehicle speed sensor (VSS) electrical connector and the 2 pin-type retainers.
20. Detach the 2 wiring harness retainers and disconnect the reversing lamp indicator switch electrical connector.
21. Disconnect the shift cables.
22. Remove the 3 shift cable bracket bolts. Position the bracket aside.
23. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
24. Disconnect the upper radiator hose.
25. Detach the heater hose support strap from the stud.
26. Disconnect the heater hoses from the heater core.
27. Disconnect the vacuum supply tube and position aside.
28. Disconnect the fuel vapor return tube. Detach the fuel vapor tube retainer from the wire harness.
29. Disconnect the fuel supply tube. See «QUICK RELEASE COUPLING - DOUBLE LOCKING»(ref-348657-S25485916692009112700000) .
30. Disconnect the PCM electrical connector and the wire harness retainer.
31. Disconnect the engine control harness electrical connector.
32. Disconnect the generator electrical connector and the 2 retainers.
33. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
34. Disconnect the lower radiator hose from the radiator.
35. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
36. Remove the rear nut and the engine support crossmember. Discard the nut.
37. Remove the 2 transaxle-to-engine bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
38. Remove the 2 engine-to-transaxle bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
39. If equipped, remove the spin on engine oil filter.
40. If equipped, remove the oil filter element.
41. Using the special tools, secure the engine to the lift table.
42. Remove the engine mount bracket bolt.
43. Remove the nuts and the engine mount bracket.
44. Remove the bolt from the transaxle rear mount.
45. Remove bolt from LH transaxle mount.
46. Lower the engine and transaxle from the vehicle.
47. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
48. Remove the nut and the ground wire.
49. Remove the 2 stud bolts and remove the starter.
50. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
51. Remove the remaining 5 engine-to-transaxle bolts and separate the engine and transaxle. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

ENGINE INSTALLATION - MANUAL TRANSAXLE

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Scheme 138

1. 1. Using the Engine Crane and Spreader Bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts. Using the Engine Crane and Spreader Bar, position the engine and transaxle onto the lift table.
2. 3. Using the special tools, secure the engine to the lift table.
3. 4. Install the starter motor isolator.
4. 5. Install the starter motor and the 2 stud bolts. Tighten to 35 N.m {3.5 kgf.m, 26 ft.lbf}.
5. 6. Install the ground wire and the nut. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
6. 7. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}. Install the starter motor solenoid nut. Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf}.
7. 8. Raise the engine and transaxle into the vehicle.
8. 9. Install the bolt in the LH transaxle mount. Tighten to 103 N.m {10.5 kgf.m, 76 ft.lbf}.
9. 10. Install the bolt in the rear transaxle mount. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
10. 11. Install the engine mount bracket and nuts. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
11. 12. Install the engine mount bracket bolt. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
12. 13. If equipped, install a new oil filter element.
13. 14. If equipped, install a new spin on engine oil filter. Lubricate the spin on oil filter gasket with clean engine oil and tighten the oil filter three-quarters turn after the oil filter gasket makes contact with the oil filter adapter.
14. 15. Install the 2 engine-to-transaxle bolts. Tighten to 48 N.m {4.9 kgf.m, 35 ft.lbf}.
15. 16. Install the 2 transaxle-to-engine bolts. Tighten to 48 N.m {4.9 kgf.m, 35 ft.lbf}.
16. 17. Install the engine support crossmember and new nut. Tighten to 175 N.m {18.4 kgf.m, 129 ft.lbf}.
17. 18. Install the 2 bolts for the engine support cross-member and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 N.m {9.1 kgf.m, 66 ft.lbf}. Tighten the front roll restrictor bolt to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
18. 19. Connect the lower radiator hose to the radiator.
19. 20. Position the A/C compressor and install the bolts Tighten the bolts to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Connect the A/C compressor electrical connector.
20. 21. Connect the generator electrical connector and attach the 2 retainers.
21. 22. Connect the engine control harness electrical connector.
22. 23. Connect the PCM electrical connector and attach the wire harness retainer.
23. 24. Connect the fuel supply quick connect coupling. See «QUICK RELEASE COUPLING - DOUBLE LOCKING»(ref-348657-S25485916692009112700000) .
24. 25. Connect the fuel vapor return tube and retainer.
25. 26. Connect the vacuum supply tube.
26. 27. Connect the heater hoses to the heater core.
27. 28. Attach the heater hose support strap to the stud.
28. 29. Connect the upper radiator hose.
29. 30. If equipped, route the block heater wiring harness and attach all the retainers. Connect the block heater electrical connector.
30. 31. Install the shift cable bracket. Position the shift cable bracket. Install the 3 bolts. Tighten to 22 N.m {2.2 kgf.m, 16 ft.lbf}.
31. 32. Connect the shift cables.
32. 33. Connect the reversing lamp indicator switch electrical connector and attach the 2 wiring harness retainers.
33. 34. Connect the vehicle speed sensor (VSS) electrical connector and attach the 2 pin-type retainers.
34. 35. Connect the clutch hydraulic line. Position the clutch hydraulic line. Connect the clutch hydraulic line to the clutch slave cylinder. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}. Install the clutch hydraulic line bracket-to-transaxle bolt. Tighten to 3 N.m {0.3 kgf.m, 27 in.lbf}.
35. 36. Position the wiring harness and attach the 2 wiring harness retainers to the battery tray bracket.
36. 37. Install the ground strap and bolt. Tighten to 10 N.m {0.1 kgf.m, 89 in.lbf}.
37. 38. Connect the electrical connector to the power distribution box (PDB).
38. 39. Connect the cable to the PDB and install the nut. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
39. 40. Install the PDB cover.
40. 41. If equipped, install the ground eyelet and bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
41. 42. Install the generator air duct and make sure the tab is latched.
42. 43. Install the accessory drive belt tensioner. See «ACCESSORY DRIVE BELT TENSIONER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S01902654092009112700000) .
43. 44. Install the exhaust downpipe and exhaust intermediate pipe.
44. 45. Install the lateral support crossmember and bolts. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
45. 46. Install the LH halfshaft and the intermediate shaft.
46. 47. Install the battery tray and battery. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) .
47. 48. Install the engine air cleaner and air cleaner outlet pipe. See «AIR CLEANER REMOVAL/INSTALLATION - 3.0L»(ref-348656-S06903233342009112700000) .
48. 49. Fill the engine with clean engine oil.
49. 50. Fill and bleed the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .
50. 51. Bleed the clutch system. See «CLUTCH SYSTEM BLEEDING»(ref-348672-S23725577962009112700000) .

ENGINE REMOVAL - AUTOMATIC TRANSAXLE

All vehicles

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Scheme 184

1. 1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-348626-S31954056142009112700000) .
2. 2. Release the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-348657-S11437714852009112700000) .
3. 3. Remove the engine air cleaner and air cleaner outlet pipe. See «AIR CLEANER REMOVAL/INSTALLATION - 3.0L»(ref-348656-S06903233342009112700000) . Remove the battery tray. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) . Drain the engine oil. Install the drain plug. To install, tighten to 28 N.m {2.8 kgf.m, 21 ft.lbf}.
4. 6. Remove the 2 front wheels and tires. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-348652-S29323856712009112700000) .
5. 7. Drain the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .
6. 8. Remove the exhaust flexible pipe. See «EXHAUST INTERMEDIATE PIPE REMOVAL/INSTALLATION»(ref-348629-S02664189312009112700000) .
7. 9. Disconnect the heated oxygen sensor (H02S) and the catalyst monitor sensor electrical connectors.
8. 10. Remove the accessory drive belt and tensioner. See «ACCESSORY DRIVE BELT REMOVAL/INSTALLATION - 2.5L»(ref-348658-S27114047842009112700000) and «ACCESSORY DRIVE BELT TENSIONER REMOVAL/INSTALLATION - 2.5L»(ref-348658-S01902654092009112700000) .
9. 11. Press the 2 (1 shown in the figure) locking tabs to release the lower air duct from the upper air duct.
10. 12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer. Remove the generator shield.
11. 13. Remove the bolts and the lateral support crossmember.
12. 14. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
13. 15. Disconnect the LH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
14. 16. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
15. 17. Disconnect the RH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
16. 18. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
17. 19. Separate the LH and RH lower control arms from the lower ball joints and position the steering knuckles aside.
18. 20. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
19. 21. Using the special tools, remove the RH half-shaft from the intermediate shaft and secure the halfshaft aside.
20. 22. Remove the 2 intermediate shaft retaining nuts.
21. 23. Remove the intermediate shaft. All wheel drive (AWD) vehicles
22. 24. Remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire. NOTE: Index-mark the driveshaft to the yoke for installation. All vehicles
23. 25. If equipped, remove the bolt and ground eyelet.
24. 26. Remove the power distribution box (PDB) cover.
25. 27. Remove the nut and disconnect the cable from the PDB.
26. 28. Disconnect the electrical connector from the PDB.
27. 29. Remove the bolt and disconnect the ground strap.
28. 30. Disconnect the 34-pin electrical connector.
29. 31. Detach the wiring harness retainers from the battery tray bracket.
30. 32. Detach the transaxle vent tube retaining clip from the engine wiring harness.
31. 33. Remove the nut holding the wiring harness bracket and unplug the transaxle electrical connector.
32. 34. Disconnect the shift cable from the transaxle manual lever.
33. 35. Detach the wiring harness pin-type retainer and remove the 2 bolts. Position the transaxle control cable and bracket aside.
34. 36. Disconnect the transaxle range sensor electrical connector.
35. 37. Disconnect the front transaxle fluid cooler tube.
36. 38. Disconnect the rear transaxle fluid cooler tube.
37. 39. Disconnect the transaxle fluid cooler tube. Disconnect the output shaft speed (OSS) sensor electrical connector (black). Disconnect the turbine shaft speed (TSS) sensor electrical connector (white). Disconnect the wiring harness retainer from the transaxle case and position the harness aside. Remove the transaxle fluid cooler retaining bracket bolt. Position the fluid cooler tube aside.
38. 40. Remove the bolt and the OSS sensor.
39. 41. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
40. 42. Disconnect the upper radiator hose.
41. 43. Detach the heater hose support strap from the heater core.
42. 44. Disconnect the heater hoses from the heater core.
43. 45. Remove the retainers and the accelerator cable snow shield.
44. 46. Disconnect the accelerator cable and speed control cable (if equipped). Disconnect the accelerator and speed control cable (if equipped) from the throttle body. Remove the bolts from the accelerator cable bracket.
45. 47. Remove the nut from the accelerator control cable bracket.
46. 48. Remove the nut from the accelerator control cable bracket. Position the accelerator control cable and bracket assembly aside.
47. 49. Disconnect the vacuum supply tube and position aside.
48. 50. Disconnect the fuel vapor return tube and retainer and position aside.
49. 51. Disconnect the fuel supply tube quick connect coupling. See «QUICK RELEASE COUPLING - DOUBLE LOCKING»(ref-348657-S25485916692009112700000) .
50. 52. Detach the electrical connector retainers.
51. 53. Remove the bolt and detach the ground wire.
52. 54. Disconnect the PCM electrical connectors. Remove the wiring harness retainer nut.
53. 55. Disconnect the lower radiator hose from the radiator.
54. 56. Disconnect the A/C compressor electrical connector and remove the 4 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
55. 57. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
56. 58. Remove the rear nut and the engine support crossmember. Discard the nut. Front wheel drive (FWD) vehicles
57. 59. Remove the 3 bolts and the dampener. All vehicles
58. 60. Remove the 2 transaxle-to-engine bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
59. 61. Remove the 2 transaxle-to-engine bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
60. 62. Using the special tools, secure the engine to the lift table.
61. 63. Remove the engine mount bracket bolt.
62. 64. Remove the nuts and the engine mount bracket.
63. 65. Remove the bolt from the transaxle rear mount.
64. 66. Remove the bolt from the LH transaxle mount.
65. 67. Lower the engine and transaxle from the vehicle.
66. 68. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
67. 69. Remove the wire harness clip retainer and the ground wire from the starter bolts.
68. 70. Remove the 2 stud bolts and remove the starter.
69. 71. Remove the starter motor isolator. AWD vehicles
70. 72. Remove the 2 lower catalytic converter bolts.
71. 73. Remove the 6 bolts and the catalytic converter heat shield.
72. 74. Remove and discard the 7 exhaust manifold nuts.
73. 75. Remove the catalytic converter and discard the exhaust manifold gasket
74. 76. Remove and discard the 7 exhaust manifold studs.
75. 77. Remove the 3 PTU bracket-to-engine bolts.
76. 78. Remove the 2 PTU bracket-to-PTU bolts and remove the bracket.
77. 79. Detach the PTU vent hose retainer.
78. 80. Remove the transaxle-to-PTU bolt.
79. 81. Remove the 3 PTU-to-transaxle bolts and the PTU. All vehicles
80. 82. Remove and discard the 4 torque converter nuts.
81. 83. Using the engine crane and spreader bar remove the engine and transaxle from the lift table.
82. 84. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.

Note. The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

ENGINE INSTALLATION - AUTOMATIC TRANSAXLE

All vehicles

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 N.m {4.9 kgf.m, 35 ft.lbf}.
2. Install the 4 new torque converter nuts. Tighten to 35 N.m {3.5 kgf.m, 26 ft.lbf}.
3. Using the Powertrain Lift and Universal Adapter Brackets, position the engine and transaxle onto the Powertrain Lift. All wheel drive (AWD) vehicles
4. Install the power transfer unit (PTU) and the 3 PTU-to-transaxle bolts. Tighten to 70 N.m {7.1 kgf.m, 52 ft.lbf}.
5. Install the transaxle-to-PTU bolt. Tighten to 48 N.m {4.9 kgf.m, 35 ft.lbf}.
6. Attach the PTU vent hose. All vehicles
7. Install the starter motor isolator.
8. Install the starter motor. Tighten to 35 N.m {3.5 kgf.m, 26 ft.lbf}.
9. Install the ground wire and the nut. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
10. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}. Install the starter motor solenoid nut. Tighten to 5 N.m {0.5 kgf.m, 44 in.lbf}.
11. Raise the engine and transaxle into the vehicle.
12. Install the bolt in the LH transaxle mount. Tighten to 103 N.m {10.5 kgf.m, 76 ft.lbf}.
13. Install the bolt in the rear transaxle mount. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
14. Install the engine mount bracket and nuts. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
15. Install the engine mount bracket bolt. Tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
16. If equipped, install a new oil filter element.
17. If equipped, install a new spin on engine oil filter. Lubricate the spin on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. AWD vehicles
18. Install the PTU bracket and the 2 PTU bracket-to-PTU bolts. Tighten to 45 N.m {4.5 kgf.m, 33 ft.lbf}.
19. Install the PTU bracket-to-engine bolt. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}.
20. Install the 4 PTU bracket-to-engine bolts. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}.
21. Install a new intermediate shaft seal and deflector. CAUTION: A new Power Transfer Unit (PTU) intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle.
22. If equipped, install the dampener and the 3 bolts. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}.
23. Install the 2 transaxle-to-engine bolts. Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}.
24. Install the 2 transaxle-to-engine bolts. Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}.
25. Install the engine support crossmember and new nut. Tighten to 175 N.m {17.5 kgf.m, 129 ft.lbf}.
26. Install the 2 bolts for the engine support cross-member and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 N.m {9.0 kgf.m, 66 ft.lbf}. Tighten the engine support crossmember bolts to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
27. Connect the lower radiator hose to the radiator.
28. Install the A/C compressor and connect the A/C compressor electrical connector. Attach the wire harness retainer. Tighten the bolts to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
29. Attach the 2 retainers and connect the generator electrical connector.
30. Connect the engine control harness electrical connector.
31. Connect the PCM electrical connector and attach the wire harness retainer.
32. Connect the fuel supply quick connect coupling. See «QUICK RELEASE COUPLING - DOUBLE LOCKING»(ref-348657-S25485916692009112700000) .
33. Connect the fuel vapor return tube. Attach the fuel vapor tube retainer to the wire harness.
34. Connect the vacuum supply tube.
35. Connect the heater hoses to the heater core.
36. Attach the heater hose support strap to the stud.
37. Connect the upper radiator hose.
38. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
39. Attach the shift cable pin-type retainer.
40. Attach the shift cable to the shift cable bracket.
41. Connect the shift cable to the transaxle manual lever.
42. Attach the 2 wiring harness retainers to the battery tray bracket.
43. Install the ground strap and bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
44. Connect the electrical connector to the power distribution box (PDB).
45. Connect the cable to the PDB and install the nut. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
46. Install the PDB cover.
47. Connect the 2 transaxle fluid cooler tubes.
48. Install the 2 secondary latches to the transaxle fluid cooler tubes.
49. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
50. Attach the wiring harness retainer to the trans-axle stud bolt.
51. Connect the transaxle electrical connector.
52. If equipped, install the ground eyelet and bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}. All wheel drive (AWD) vehicles
53. Position the driveshaft to the PTU and install the 6 bolts. Tighten to 37 N.m {3.7 kgf.m, 27 ft.lbf}. All vehicles
54. Install the generator air duct and make sure the tab is latched.
55. Install the accessory drive belt.
56. Install the exhaust downpipe and exhaust intermediate pipe.
57. Install the lateral support crossmember and bolts. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
58. Install the LH halfshaft and the intermediate shaft.
59. Install the battery tray and battery. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) .
60. Install the engine air cleaner and air cleaner outlet pipe. See «AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION - 2.5L»(ref-348655-S38737774142009112700000) .
61. Fill the engine with clean engine oil.
62. Fill and bleed the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.5L»(ref-348664-S29598792362009112700000) .
63. Check and fill the transmission fluid as necessary. AWD vehicles
64. Check and fill the PTU fluid as necessary.

Scheme 200

1. For additional information, see the procedures in this service information.

Scheme 201

1. For additional information, see the procedures in this service information.