Engine Mechanical - Hybrid: Removal & Installation Mazda Tribute II

ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
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. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
4. To install, reverse the removal procedure.

ACCESSORY DRIVE BELT TENSIONER - HYBRID REMOVAL/INSTALLATION

1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the tensioner pulley.
2. Remove the 3 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.
3. To install, reverse the removal procedure.

Scheme 660

Scheme 661

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG REMOVAL/INSTALLATION - 2.5L»(ref-373094-S27342411722010100600000) .
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.

Scheme 662

Scheme 663

1. Clean and inspect the sealing 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.
2. Apply silicone gasket and sealant to the locations shown in illustration. 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.
3. Install the valve cover, gasket and retainers. Tighten in the sequence shown in illustration to 10 N.m {1.0 kgf.m, 89 in.lbf}. NOTE: Clean and inspect the gasket. Install a new gasket, if necessary.
4. Install the oil level indicator.
5. Connect the VCT solenoid electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the CMP sensor electrical connector.
8. Attach the 3 wire harness retainers to the valve cover stud bolts.
9. Install the 4 engine cover studs.
10. Connect the crankcase vent hose to the valve cover.
11. Install the ignition coil-on-plugs. See «IGNITION COIL-ON-PLUG REMOVAL/INSTALLATION - 2.5L»(ref-373094-S27342411722010100600000) .

Scheme 664

Scheme 665

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

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the front RH wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
3. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
4. Remove the valve cover. See «VALVE COVER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S04330418122010100600000) .
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 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

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 (one-quarter 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 one and three-quarters turn. 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 - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
18. Install the front RH wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
19. Install the valve cover. See «VALVE COVER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S04330418122010100600000) .

Scheme 684

1. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY - HYBRID REMOVAL/INSTALLATION»(ref-373078-S33892544902010100600000) .
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 685

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 - HYBRID REMOVAL/INSTALLATION»(ref-373078-S33892544902010100600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the engine. See «ENGINE - AUTOMATIC TRANSAXLE REMOVAL - HYBRID»(ref-373078-S05688208412010100600000) .
3. Remove the 6 bolts and the flexplate.

Scheme 686

1. Install the flexplate and tighten the bolts in the sequence shown in illustration 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 engine. See «ENGINE - AUTOMATIC TRANSAXLE REMOVAL - HYBRID»(ref-373078-S05688208412010100600000) .

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the flexplate. See «FLEXPLATE - HYBRID REMOVAL/INSTALLATION»(ref-373078-S18526692272010100600000) .
3. Drain the engine oil. Install the drain plug. 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.
5. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

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 illustration 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 two 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. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
5. Install the oil pan. Install the 2 oil pan bolts finger-tight.
6. Install the 4 bolts. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
7. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
8. Install the flexplate. See «FLEXPLATE - HYBRID REMOVAL/INSTALLATION»(ref-373078-S18526692272010100600000) .
9. Fill the engine with clean engine oil.

Scheme 692

Scheme 693

Scheme 694

Scheme 695

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the accessory drive belt and idler pulleys. See «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) and «ACCESSORY DRIVE BELT TENSIONER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S24857711742010100600000) .
3. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY - HYBRID REMOVAL/INSTALLATION»(ref-373078-S33892544902010100600000) .
4. Remove the engine mount. See «ENGINE MOUNT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S40954535902010100600000) .
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. Disconnect the crankshaft position (CKP) sensor electrical connector.
8. Remove the 2 bolts and the CKP sensor.
9. Remove the bolts and the engine front cover.

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

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 illustration, 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. Using the special tool, install the crankshaft front oil seal. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer. NOTE: Lubricate the oil seal with clean engine oil.
5. Install the water pump pulley and the 3 bolts. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
6. Install the engine mount. See «ENGINE MOUNT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S40954535902010100600000) .
7. Install the crankshaft pulley. See «CRANKSHAFT PULLEY - HYBRID REMOVAL/INSTALLATION»(ref-373078-S33892544902010100600000) .
8. 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.
9. Install a new CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
10. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 N.m {0.7 kgf.m, 62 in.lbf}.
11. Connect the CKP sensor electrical connector.
12. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
13. Install the accessory drive belt and idler pulleys. See «ACCESSORY DRIVE BELT TENSIONER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S24857711742010100600000) and «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

1. With vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the engine front cover. See «ENGINE FRONT COVER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S25966963282010100600000) .
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 2 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 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

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 «ENGINE FRONT COVER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S25966963282010100600000) .

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Disconnect the battery ground cable.
3. Depower the vehicle High Voltage Traction Battery (HVTB) electrical system. See «HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID»(ref-373092-S23272902992010100600000) .
4. Remove the degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - HYBRID»(ref-373089-S12639818932010100600000) .
5. Remove the DC/DC converter. See «DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER REMOVAL/INSTALLATION - HYBRID»(ref-373092-S07266958632010100600000) .
6. Check the valve clearance. See «VALVE CLEARANCE CHECK -- 2.5L»(ref-348662-S02570884572009112700000) .
7. Remove the front RF wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
8. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
9. 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.
10. 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.
11. Remove the engine bolt plug.
12. 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.
13. 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.
14. Remove the front cover timing hole plug from the engine front cover.
15. Remove the upper front cover timing hole plug from the engine front cover.
16. Reposition the special tool to the slot on the rear of the intake camshaft only.
17. 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 18 mm (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.
18. Remove the special tool.
19. Using the flats of the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
20. Remove the timing chain from the camshaft phaser and sprocket.
21. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
22. 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.
23. 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 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

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 illustration 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 - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
15. Install the front RF wheel and tire. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
16. Install the valve cover. See «VALVE COVER - HYBRID REMOVAL/INSTALLATION»(ref-373078-S04330418122010100600000) .
17. Install the DC/DC converter. See «DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER REMOVAL/INSTALLATION - HYBRID»(ref-373092-S07266958632010100600000) .
18. Install the degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - HYBRID»(ref-373089-S12639818932010100600000) .
19. Repower the vehicle High Voltage Traction Battery (HVTB) electrical system. See «HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID»(ref-373092-S23272902992010100600000) .
20. Connect the battery ground cable.

Scheme 742

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the camshafts. See «CAMSHAFTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S35172143962010100600000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S22732400442010100600000) and «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-373094-S33731314972010100600000) .
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.

Scheme 743

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-373094-S33731314972010100600000) .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. See «CAMSHAFTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S35172143962010100600000) .

Scheme 744

Scheme 745

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the camshafts. See «CAMSHAFTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S35172143962010100600000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S22732400442010100600000) and «VALVE TAPPET INSPECTION -- 2.5L»(ref-348662-S35820008322009112700000) . 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-373094-S33731314972010100600000) .
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 746

Scheme 747

Scheme 748

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-373094-S33731314972010100600000) .
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 - HYBRID REMOVAL/INSTALLATION»(ref-373078-S35172143962010100600000) .

VALVE TAPPETS - HYBRID REMOVAL/INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the camshafts. See «CAMSHAFTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S35172143962010100600000) .
3. Remove and inspect the valve tappets. See «VALVE TAPPETS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S22732400442010100600000) and «VALVE TAPPET INSPECTION -- 2.5L»(ref-348662-S35820008322009112700000) . 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 749

Scheme 750

Scheme 751

Scheme 752

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
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 - HYBRID»(ref-373089-S41502309662010100600000) .
4. Remove the timing drive components. See «TIMING DRIVE COMPONENTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S27158835022010100600000) .
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 - HYBRID»(ref-373096-S31470298222010100600000) .
11. Remove the catalytic converter exhaust manifold. See «CATALYTIC CONVERTER UNDERBODY REMOVAL/INSTALLATION - HYBRID»(ref-373097-S26843625692010100600000) .
12. Disconnect the EGR valve electrical connector.
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. Discard the bolts and the cylinder head gasket.

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

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 illustration.
5. Install a new head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration 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.
7. Connect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose to the engine coolant outlet and the EGR valve.
8. Connect the EGR valve electrical connector.
9. Install the catalytic converter. See «CATALYTIC CONVERTER UNDERBODY REMOVAL/INSTALLATION - HYBRID»(ref-373097-S26843625692010100600000) .
10. Install the intake manifold. See «INTAKE MANIFOLD REMOVAL/INSTALLATION - HYBRID»(ref-373096-S31470298222010100600000) .
11. Install the valve tappets in their original positions. NOTE: Lubricate the valve tappets with clean engine oil.
12. Install the camshaft 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 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, 141 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.
13. Install the special tool.
14. Install the timing drive components. See «TIMING DRIVE COMPONENTS - HYBRID REMOVAL/INSTALLATION»(ref-373078-S27158835022010100600000) .
15. Fill and bleed the engine cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - HYBRID»(ref-373089-S41502309662010100600000) .

Scheme 758

Scheme 759

Scheme 760

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Remove the degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - HYBRID»(ref-373089-S12639818932010100600000) .
3. Remove the DC/DC converter. See «DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER REMOVAL/INSTALLATION - HYBRID»(ref-373092-S07266958632010100600000) .
4. Install the special tool.
5. Remove the engine mount bracket bolt. To install, tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
6. Use the special tool to raise the engine 25 mm (9.98 in).
7. Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 N.m {11.7 kgf.m, 85 ft.lbf}.
8. Remove the A/C tube bracket nut. To install, tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
9. Rotate the A/C tube brackets off of the studs. Reposition the A/C tubes to access the engine mount bolt.
10. Remove the 3 bolts and the engine mount. To install, tighten to 55 N.m {5.6 kgf.m, 41 ft.lbf}.
11. To install, reverse the removal procedure.

ENGINE - AUTOMATIC TRANSAXLE REMOVAL - HYBRID

All vehicles

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

1. With the vehicle in NEUTRAL, position it on a hoist. See «LIFTING»(ref-373073-S06960946762010100600000) .
2. Release the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-348657-S11437714852009112700000) .
3. Remove the battery tray. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) .
4. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position. NOTE: Use a steering wheel holding device (such as 28-75-1 or equivalent).
5. Disable the vehicle high voltage electrical system. See «HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID»(ref-373092-S23272902992010100600000)
6. Drain the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING -- 2.5L»(ref-348664-S29598792362009112700000) .
7. Drain the Motor Electronics Cooling System (MECS).
8. Remove the engine coolant degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - HYBRID»(ref-373089-S12639818932010100600000) .
9. Remove the engine air cleaner. See «AIR CLEANER REMOVAL/INSTALLATION - HYBRID»(ref-373096-S19911542102010100600000) .
10. Remove the accessory drive belt. See «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
11. Disconnect the fuel supply tube.
12. Remove the 2 front wheels and tires. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
13. Remove the bolts and the lateral support crossmember.
14. Remove the exhaust intermediate pipe. See «EXHAUST INTERMEDIATE PIPE REMOVAL/INSTALLATION - HYBRID»(ref-373097-S30958937762010100600000) .
15. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
16. Disconnect the LH suspension. Remove the nut and disconnect the stabilizer bar link. Remove and discard the tie-rod end retaining nut.
17. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
18. Disconnect the RH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
19. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle. NOTE: LH shown in illustration, RH similar.
20. Remove the RH and LH halfshafts. See «FRONT DRIVE HALFSHAFTS REMOVAL/INSTALLATION»(ref-373098-S05291000092010100600000) .
21. Remove the 2 intermediate shaft bearing retainer nuts.
22. Remove the intermediate shaft. NOTE: On All-Wheel Drive (AWD) vehicles, the Power Transfer Unit (PTU) seal must be replaced every time the intermediate shaft is removed.
23. Drain the transmission fluid.

All wheel drive (AWD) vehicles

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

1. Remove the driveshaft. See «DRIVESHAFT REMOVAL/INSTALLATION»(ref-373099-S12257131422010100600000) .
2. Remove the 2 catalytic converter bracket bolts.
3. Remove the 6 bolts and the Power Transfer Unit (PTU)-to-engine bracket. NOTE: Catalytic converter manifold is removed for clarity.
4. Remove the 3 PTU heat shield bolts and the PTU heat shield.
5. Disconnect the PTU vent hose and position it aside.
6. Remove the 4 PTU-to-transaxle bolts and remove the PTU. NOTE: Catalytic converter manifold removed for clarity.
7. Using the halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

Scheme 810

1. If equipped, remove the spin-on engine oil filter.
2. If equipped, remove the oil filter element.
3. Drain the engine oil. Install the drain plug. Tighten to 28 N.m {28.0 kgf.m, 21 ft.lbf}.
4. Disconnect the heater hoses from the heater core.
5. Disconnect the upper radiator hose from the radiator.
6. Disconnect the brake booster vacuum tube from the brake booster.
7. Disconnect the PCM center electrical connector. Remove the wiring harness retainer.
8. If equipped, disconnect the block heater electrical connector. Detach the harness retainer clips and position harness aside.
9. Disconnect the engine control harness electrical connector.
10. Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge valve.
11. Remove the transaxle selector lever cable fasteners from the stud bolts on the transaxle.
12. Remove the transaxle selector lever cable fastener from the intake manifold.
13. Remove the stud bolt and disconnect the transaxle harness electrical connector.
14. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
15. Disconnect the coolant vent hose.
16. Release the locking tab and disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers.
17. Remove the 3 nuts and position aside the DC-to-DC converter.
18. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
19. Disconnect the transaxle coolant hoses.
20. Remove the bolts and the transaxle control snow shield.
21. Disconnect the transaxle control cable. Release the transaxle control cable from the control lever. Remove the nuts from the transaxle control cable bracket.
22. Remove the 2 harness fasteners, the nut and the ground cable.
23. Disconnect the MECS pump electrical connector and detach the harness retainer.
24. Remove the 2 bolts and position the MECS pump and ground strap aside.
25. Remove the nut from the accelerator control cable bracket.
26. Remove the nut from the accelerator control cable bracket. Position the accelerator control cable and bracket assembly aside.
27. Disconnect the vacuum supply tube and position aside.
28. Disconnect the fuel vapor return tube and retainer and position aside.
29. Disconnect the fuel supply tube quick connect coupling. See «QUICK RELEASE COUPLING -- DOUBLE LOCKING»(ref-348657-S25485916692009112700000) .
30. Detach the electrical connector retainers.
31. Remove the bolt and detach the ground wire.
32. Disconnect the PCM electrical connectors. Remove the wiring harness retainer nut.
33. Disconnect the lower radiator hose from the radiator.
34. 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.
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.

Scheme 811

1. Remove the 3 bolts and the dampener.

All vehicles

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

1. Remove the 2 transaxle-to-engine bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
2. Remove the 2 transaxle-to-engine bolts. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
3. Using the special tools, secure the engine to the lift table.
4. Remove the engine mount bracket bolt.
5. Remove the nuts and the engine mount bracket.
6. Remove the bolt from the transaxle rear mount.
7. Remove the bolt from the LH transaxle mount.
8. Lower the engine and transaxle from the vehicle.
9. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
10. Remove the wire harness clip retainer and the ground wire from the starter bolts.
11. Remove the 2 stud bolts and remove the starter.
12. Remove the starter motor isolator.

AWD vehicles

Scheme 823

Scheme 824

Scheme 825

Scheme 826

Scheme 827

Scheme 828

Scheme 829

Scheme 830

1. Remove the 2 lower catalytic converter bolts.
2. Remove the 6 bolts and the catalytic converter heat shield.
3. Remove and discard the 7 exhaust manifold nuts.
4. Remove the catalytic converter and discard the exhaust manifold gasket.
5. Remove and discard the 7 exhaust manifold studs.
6. Remove the 3 PTU bracket-to-engine bolts.
7. Remove the 2 PTU bracket-to-PTU bolts and remove the bracket.
8. Detach the PTU vent hose retainer.
9. Remove the transaxle-to-PTU bolt.
10. Remove the 3 PTU-to-transaxle bolts and the PTU.

All vehicles

Scheme 831

1. Remove and discard the 4 torque converter nuts.
2. Using the engine crane and spreader bar remove the engine and transaxle from the lift table.
3. 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 - AUTOMATIC TRANSAXLE INSTALLATION - HYBRID

Installation

All vehicles

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

Scheme 847

Scheme 848

Scheme 849

Scheme 850

Scheme 851

Scheme 852

1. Install the transaxle damper. Tighten to 29 N.m {2.9 kgf.m, 21 ft.lbf}. NOTE: Due to packaging requirements the correct bolt must be used at the damper locations. NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}. NOTE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft. NOTE: Transaxle removed from view for clarity.
3. Connect the high voltage wiring harness electrical connector. Engage the electrical connector locking tab.
4. Using the Heavy Duty Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.
5. Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
6. Raise the engine and transaxle into the vehicle.
7. Install the upper transaxle insulator. Tighten the nuts to 90 N.m {9.0 kgf.m, 66 ft.lbf}. Tighten the through bolt to 103 N.m {10.3 kgf.m, 76 ft.lbf}.
8. Install the upper transaxle insulator bracket. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
9. Install the 3 engine mount bracket nuts. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
10. Install the engine mount bracket bolt. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
11. Using the Powertrain Lift, raise the subframe into position.
12. Install the 2 subframe nuts. Tighten to 150 N.m {15.0 kgf.m, 111 ft.lbf}.
13. Tighten the 2 subframe bolts. Tighten to 175 N.m {17.5 kgf.m, 129 ft.lbf}.
14. Install the rear roll restrictor, bracket and bolts. Tighten to 55 N.m {5.5 kgf.m, 41 ft.lbf}.
15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}.
16. Install the rear transaxle insulator through bolt. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
17. Install the 2 transaxle-to-engine bolts. Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}.
18. Install the 2 transaxle-to-engine bolts. Tighten to 48 N.m {4.8 kgf.m, 35 ft.lbf}.
19. Install the engine support crossmember. Tighten the bolts to 90 N.m {9.0 kgf.m, 66 ft.lbf}. Tighten the new nut to 175 N.m {17.5 kgf.m, 129 ft.lbf}.
20. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 90 N.m {9.0 kgf.m, 66 ft.lbf}.
21. Install the lower transaxle insulator through bolt. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
22. Connect the lower radiator hose to the radiator.
23. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
24. Install the auxiliary coolant pump and the electrical connector. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
25. Install the Motor Electronics Cooling System (MECS) pump and the ground strap. Install the 2 bolts. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
26. Connect the MECS pump electrical connector and attach the harness retainer.
27. Install the wiring harness fasteners, the ground cable and nut. Tighten to 20 N.m {2.0 kgf.m, 177 in.lbf}.
28. Connect the transaxle control cable. Install the transaxle control cable bracket and the 2 nuts finger-tight. Attach the transaxle control cable to the control lever.
29. Position the control lever between the 2 casting ribs on the transaxle case.
30. Place the gear selector lever in the D position.
31. Tighten the transaxle control cable bracket nuts. Tighten to 22 N.m {2.2 kgf.m, 16 ft.lbf}.
32. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
33. Install the transaxle control snow shield. Tighten to 22 N.m {2.2 kgf.m, 16 ft.lbf}.
34. Connect the transaxle coolant hoses.
35. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
36. Position the DC-to-DC converter in place and install the 3 nuts. Tighten to 12 N.m {1.2 kgf.m, 106 in.lbf}.
37. Connect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown in illustration). Engage the electrical connector locking tab.
38. Connect the coolant vent hose.
39. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
40. Connect the transaxle harness electrical connector and install the stud bolt. Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.
41. Connect the transaxle selector lever cable fastener to the intake manifold.
42. Install the transaxle selector lever cable fasteners on the transaxle stud bolts.
43. Connect the upper evaporative emissions Evaporative Emission (EVAP) tube quick connect coupling to the purge valve.
44. Connect the engine control harness electrical connector.
45. If equipped, connect the block heater electrical connector. Attach the harness retainer clips.
46. Connect the PCM electrical connector. Position the harness and install the wiring harness retainer.
47. Connect the brake booster vacuum hose to the brake booster.
48. Connect the upper radiator hose to the radiator.
49. Connect the heater hoses to the heater core.
50. If equipped, install the spin-on engine oil filter. Tighten the spin-on oil filter three-quarters of a turn after the oil filter gasket makes contact with the oil filter adapter.
51. If equipped, install the oil filter element. NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.

All wheel drive (AWD) vehicles

Scheme 853

Scheme 854

Scheme 855

1. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
2. Position the Power Transfer Unit (PTU) in place and install the 4 bolts. Tighten to 45 N.m {4.5 kgf.m, 33 ft.lbf}.
3. Connect the PTU vent hose.
4. Install the PTU heat shield and the bolts. Tighten to 11 N.m {1.1 kgf.m, 97 in.lbf}.
5. Position the PTU-to-engine support bracket and install the bolts. Tighten to 40 N.m {4.0 kgf.m, 30 ft.lbf}. NOTE: Catalytic converter manifold is removed for clarity.
6. Install the 2 exhaust bracket bolts. Tighten to 25 N.m {2.5 kgf.m, 18 ft.lbf}.
7. Install the driveshaft.

All vehicles

Scheme 856

Scheme 857

Scheme 858

Scheme 859

Scheme 860

Scheme 861

Scheme 862

1. Connect the RH and LH suspension. Position the tie-rod end and install the retaining nut. Tighten to 55 N.m {5.5 kgf.m, 41 ft.lbf}. Connect the stabilizer bar link and install the nut. Tighten to 63 N.m {6.3 kgf.m, 46 ft.lbf}. NOTE: RH side shown in illustration, LH similar.
2. Install the intermediate shaft.
3. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 N.m {2.7 kgf.m, 20 ft.lbf}.
4. Install the RH brake hose retainer and the ABS sensor bolt. Tighten to 15 N.m {1.5 kgf.m, 133 in.lbf}.
5. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 N.m {1.5 kgf.m, 133 in.lbf}.
6. Install the exhaust intermediate pipe.
7. Install the lateral support crossmember and the bolts. Tighten to 115 N.m {11.5 kgf.m, 85 ft.lbf}.
8. Install the front wheels and tires. See «WHEEL AND TIRE REMOVAL/INSTALLATION»(ref-373095-S28507114572010100600000) .
9. Connect the fuel supply tube.
10. Install the accessory drive belt. See «ACCESSORY DRIVE BELT - HYBRID REMOVAL/INSTALLATION»(ref-373078-S34131091992010100600000) .
11. Install the engine coolant degas bottle. See «DEGAS BOTTLE REMOVAL/INSTALLATION - HYBRID»(ref-373089-S12639818932010100600000) .
12. Install the battery and the battery tray. See «BATTERY TRAY REMOVAL/INSTALLATION»(ref-348661-S24681863762009112700000) .
13. Install the engine air cleaner. See «AIR CLEANER REMOVAL/INSTALLATION - HYBRID»(ref-373096-S19911542102010100600000) .
14. Fill the engine with clean engine oil.
15. Enable the vehicle high voltage electrical system. See «HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING - HYBRID»(ref-373092-S23272902992010100600000) .
16. Reset the Passive Anti-Theft System (PATS).
17. Fill and bleed the MECS. See «MOTOR ELECTRONICS COOLING SYSTEM DRAINING AND FILLING - HYBRID»(ref-373100-S24369531972010100600000) .
18. Fill and bleed the cooling system. See «COOLING SYSTEM DRAINING, FILLING AND BLEEDING -- 2.5L»(ref-348664-S29598792362009112700000) .
19. Fill the transaxle with fluid.

Scheme 863

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

Scheme 864

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

Scheme 865

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

Scheme 866

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