Engine - 2.3L - (Except Hybrid): Removal & Installation Mercury Mariner II

REMOVAL AND INSTALLATION

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-292210) article.
3. Remove the throttle body. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-292210) article.
4. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-292207-S33905664042008073100000) .
5. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
6. Disconnect the fuel vapor return hose from the intake manifold.
7. Remove the 3 bolts and position the accelerator cable bracket aside. To install, tighten to 10 Nm (89 lb-in).
8. Disconnect the idle air control (IAC) motor electrical connector.
9. Disconnect the swirl control valve electrical connector.
10. Disconnect the knock sensor (KS) electrical connector. Detach the electrical connector pin-type retainer.
11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
12. Disconnect the engine oil pressure (EOP) switch electrical connector. Detach the wiring harness pin-type retainer and position the wiring harness aside.
13. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. To install, tighten to 18 Nm (13 lb-ft).
14. Release the clamp and disconnect the crankcase vent hose.
15. Remove the EGR tube. To install, tighten to 55 Nm (41 lb-ft).
16. Remove the intake manifold and gaskets.
17. To install, reverse the removal procedure. Inspect and install new intake manifold gaskets if necessary.

Scheme 9

Scheme 10

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.
3. Disconnect the crankcase vent hose.
4. Disconnect the camshaft position (CMP) sensor electrical connector.
5. Disconnect the fuel rail pressure and temperature sensor electrical connector.
6. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
7. Disconnect the radio capacitor electrical connector.
8. Remove the 2 accelerator cable bracket nuts. Position the accelerator cable and brackets aside.
9. Detach all of the wiring harness retainers from the valve cover studs and position the harness aside.
10. Remove the 14 valve cover retainers, the valve cover and gasket.

INSTALLATION

1. Clean and inspect the sealing surfaces.
2. Install the valve cover, gasket and retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs.
4. Install the accelerator control cable brackets and nuts. Tighten to 6 Nm (53 lb-in).
5. Connect the radio capacitor electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the fuel rail pressure and temperature sensor electrical connector.
8. Connect the CMP sensor electrical connector.
9. Connect the crankcase vent hose.
10. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.

Scheme 11

Scheme 12

1. For additional information, refer to the procedures in this article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the front RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
4. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-292207-S16433314052008073100000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the special tool in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the special tool.
9. Assemble the special tools using 4 hardened washers in the locations shown.
10. Using the special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.

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.
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.
4. Assemble the special tools using 4 hardened washers in the locations shown.
5. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
6. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
7. Remove the special tool.
8. Remove the special tool.
9. Turn the crankshaft clockwise 1 and 3/4 turns.
10. Install the special tool.
11. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
12. 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.
13. 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.
14. Remove the special tool.
15. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
16. Remove the special tool.
17. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
18. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
19. Install the front RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
20. Install the valve cover. For additional information, refer to «Valve Cover»(ref-292207-S16433314052008073100000) .

1. Remove the crankshaft pulley. For additional information, refer to «Lower End Components - Exploded View»(ref-292207-S23905584072008073100000) and «Crankshaft Pulley»(ref-292207-S01480933782008073100000) .
2. Using the special tool, remove the crankshaft front oil seal.

1. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «Lower End Components - Exploded View»(ref-292207-S23905584072008073100000) and «Crankshaft Pulley»(ref-292207-S01480933782008073100000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - CD4E»(ref-292152) article.
3. Remove the 6 bolts and the flexplate.

1. Install the flexplate and tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - CD4E»(ref-292152) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-292212) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-292196) article.
3. Remove the 6 bolts and the flywheel.

1. Install the flywheel and tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the clutch and manual transaxle. For additional information, refer to «CLUTCH»(ref-292212) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-292196) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-292207-S17108327832008073100000) or «Flywheel»(ref-292207-S17685045252008073100000) .
3. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
4. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-292207-S33905664042008073100000) .
5. Remove the 17 bolts and the oil pan.
6. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

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. To install, tighten in the sequence shown to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan and cylinder block mating surfaces.
4. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
5. Install the 4 bolts. To install, tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
7. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-292207-S33905664042008073100000) .
8. Install the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-292207-S17108327832008073100000) or «Flywheel»(ref-292207-S17685045252008073100000) .
9. Fill the engine with clean engine oil.

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

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the accessory drive belt and idler pulleys. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
3. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-292207-S01480933782008073100000) .
4. Remove the engine mount. For additional information, refer to «Engine Mount»(ref-292207-S25886773142008073100000) .
5. Using the special tool, remove the crankshaft front oil seal.
6. Remove the 3 bolts and the coolant pump pulley.
7. Remove the 3 bolts and the accessory drive belt idler pulley and bracket.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove and discard the CKP sensor.
10. Remove the bolts and the engine front cover.

1. Clean and inspect the mounting surfaces of the engine and the front cover.
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.
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8 mm bolts to 10 Nm (89 lb-in). Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
4. Install the accessory drive belt idler pulley and bracket and the 3 bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
5. Install the coolant pump pulley and bolts. Tighten to 20 Nm (15 lb-ft).
6. Using the special tool, install the crankshaft front oil seal.
7. Install the engine mount. For additional information, refer to «Engine Mount»(ref-292207-S25886773142008073100000) .
8. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-292207-S01480933782008073100000) .
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.
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 Nm (62 lb-in).
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. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292207-S20432374162008073100000) .
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 RH timing chain guide.
5. Remove the timing chain.
6. Remove the bolts and the LH timing chain guide.
7. Remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and the bolts. To install, tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the RH timing chain guide.
5. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
7. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292207-S20432374162008073100000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-292207-S21109203422008073100000) .
3. Remove the front RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
4. Remove the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the special tool in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the special tool.
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.
10. Remove the lower front cover timing hole plug from the engine front cover.
11. Remove the upper front cover timing hole plug from the engine front cover.
12. Reposition the special tool to the slot on the rear of the intake camshaft only.
13. 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.
14. Remove the special tool.
15. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
16. Remove the timing chain from the intake camshaft drive gear.
17. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
18. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
19. 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 camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.

1. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
2. Install the special tool.
3. Install the intake camshaft drive gear and hand-tighten the bolt.
4. Install the timing chain on the intake camshaft drive gear.
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.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
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 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug. Install the plug and tighten to 12 Nm (9 lb-ft).
13. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
14. Install the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
15. Install the front RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
16. Install the valve cover. For additional information, refer to «Valve Cover»(ref-292207-S16433314052008073100000) .

Scheme 13

1. For additional information, refer to the procedures in this article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-292207-S26328204832008073100000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292155) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.
5. Connect the compressed air supply to cylinder No. 1.
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.

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.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «Camshafts»(ref-292207-S26328204832008073100000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-292207-S26328204832008073100000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292155) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.
5. Connect the compressed air supply to cylinder No. 1.
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.
7. Using the special tools, remove and discard the valve seal.

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.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-292211) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «Camshafts»(ref-292207-S26328204832008073100000) .

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-292207-S26328204832008073100000) .
3. Remove and inspect the valve tappets. For additional information refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292155) article.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.
4. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(ref-292207-S07699651962008073100000) .
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 camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
8. Remove the valve tappets.
9. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292155) article.
10. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-292207-S13696768952008073100000) .
11. Remove the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-292214) article.
12. Remove the catalytic converter exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
13. Disconnect the EGR valve electrical connector.
14. Disconnect the EGR coolant hose from the EGR valve.
15. Detach the wire harness retainer from the coolant outlet stud bolt.
16. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
17. Remove the 10 bolts and the cylinder head. Discard the bolts and the cylinder head gasket.

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292155) article.
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.
5. Install a new head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
8. Attach the wire harness retainer to the coolant outlet stud bolt.
9. Connect the EGR coolant hose to the EGR valve.
10. Connect the EGR valve electrical connector.
11. Install the exhaust manifold. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
12. Install the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-292214) article.
13. Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-292207-S13696768952008073100000) .
14. Install the valve tappets in their original positions.
15. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
16. Install the special tool.
17. Install the timing drive components. For additional information, refer to «Timing Drive Components»(ref-292207-S07699651962008073100000) .
18. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.

Scheme 14

Scheme 15

Note. Automatic transmission shown, manual transmission similar.

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. For additional information, refer to the procedures in this article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the 5 bolts, the pin-type retainer (not shown), and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the spin on oil filter. To install, tighten the spin on oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
5. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
6. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the pin-type retainer, 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the engine oil pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure. Apply thread sealant to the EOP switch threads.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
3. Loosen the 2 top bellhousing-to-engine bolts 5 mm (0.19 in).
4. Working from the top of the vehicle, loosen the 2 rear lower engine-to-bellhousing bolts 5 mm (0.19 in).
5. Working from under the vehicle, loosen the 2 upper engine bracket-to-power transfer unit (PTU) bolts 5 mm (0.19 in).
6. Remove the pin-type retainer, 6 bolts and the LH splash shield.
7. Remove the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-292207-S33905664042008073100000) .
8. Loosen the 2 front lower bellhousing-to-engine bolts 5 mm (0.19 in).
9. Loosen the 1 (manual transaxle) and 2 (automatic transaxle) rear lower engine-to-bellhousing bolt 5 mm (0.19 in).
10. Remove the 2 oil pan-to-bellhousing bolts.
11. Remove the 2 bellhousing-to-oil pan bolt.
12. Slide the transaxle rearward 5 mm (0.19 in).
13. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
14. Remove the 4 engine front cover-to-oil pan bolts.
15. Remove the 13 bolts and the oil pan.

All vehicles

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
6. Alternate tightening the 1 front and 1 rear lower bolts to slide the transaxle and engine together. Tighten to 48 Nm (35 lb-ft).
7. Tighten the remaining front lower bolt and rear lower bolt (automatic transaxle). Tighten to 48 Nm (35 lb-ft).
8. Alternate tightening the 1 upper engine-to-PTU bracket bolt and 1 front lower bolt to slide transaxle and engine together. Tighten the PTU bracket bolt to 45 Nm (33 lb-ft). Tighten the front lower bolt to 48 Nm (35 lb-ft).
9. Tighten the remaining upper engine-to-PTU bracket bolt. Tighten to 45 Nm (33 lb-ft).
10. Tighten the remaining front lower bolt. Tighten to 48 Nm (35 lb-ft).
11. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the oil level indicator and tube. For additional information, refer to «Oil Level Indicator and Tube»(ref-292207-S33905664042008073100000) .
14. Install the LH splash shield and the pin-type retainers and 6 bolts. Tighten to 9 Nm (80 lb-in).
15. Working from the top of vehicle, tighten the 2 rear lower engine-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
16. Tighten the 2 top bellhousing-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
17. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
18. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-292207-S06899465872008073100000) and «Oil Pan»(ref-292207-S24402176852008073100000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292207-S20432374162008073100000) .
3. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 4 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.
6. Remove the 2 bolts and the oil pump screen and pickup tube.
7. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner.
8. Remove the chain from the oil pump sprocket.
9. Remove the bolt and oil pump sprocket.
10. Remove the 4 bolts and the oil pump.

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Clean all mating surfaces with metal surface prep.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
11. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-292207-S20432374162008073100000) .
13. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Remove the oil level indictor.
3. Remove the pin-type retainer, the 5 bolts and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
4. Detach the wire harness retainer from the oil indicator tube.
5. Remove the bolt and the oil level indicator tube. To install, tighten to 10 Nm (89 lb-in).
6. Remove and discard the oil level indicator tube O-ring seal.
7. To install, reverse the removal procedure. Lubricate a new O-ring seal with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Install the Engine Support Bar.
3. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
4. Use the Engine Support Bar to raise the engine 25 mm (0.98 in).
5. Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 Nm (85 lb-ft).
6. Remove the 3 bolts and the engine mount. To install, tighten to 55 Nm (41 lb-ft).
7. To install, reverse the removal procedure.

Engine - Automatic Transaxle

Special Tools Illustration Tool Name Tool Number Front Drive Halfshaft Remover 205-241 (T86P-3514-A) Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Tie-Rod End Remover 211-105 (T85M-3395-A) Universal Adapter Brackets 014-0001

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
3. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
4. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
5. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
6. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.
8. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
9. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
10. Remove the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
11. Press the 2 locking tabs (1 shown) to release the lower air duct from the upper air duct.
12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer. Remove the generator shield.
13. Remove the bolts and the lateral support crossmember.
14. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
15. Disconnect the LH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
16. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
17. Disconnect the RH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
18. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
19. Separate the LH and RH lower control arms from the lower ball joints and position the steering knuckles aside.
20. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
21. Using the special tools, remove the RH halfshaft from the intermediate shaft and secure the halfshaft aside.
22. Remove the 2 intermediate shaft retaining nuts.
23. Remove the intermediate shaft.
24. Remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire.
25. If equipped, remove the bolt and ground eyelet.
26. Remove the power distribution box (PDB) cover.
27. Remove the nut and disconnect the cable from the PDB.
28. Disconnect the electrical connector from the PDB.
29. Remove the bolt and the ground strap.
30. Disconnect the 34-pin electrical connector.
31. Detach the wiring harness retainers from the battery tray bracket.
32. Detach the transaxle vent tube retaining clip from the engine wiring harness.
33. Remove the nut holding the wiring harness bracket and unplug the transaxle electrical connector.
34. Disconnect the shift cable from the transaxle manual lever.
35. Detach the wiring harness pin-type retainer and remove the 2 bolts. Position the transaxle cable and bracket aside.
36. Disconnect the transaxle range sensor electrical connector.
37. Disconnect the front transaxle fluid cooler tube.
38. Disconnect the rear transaxle fluid cooler tube.
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.
40. Remove the bolt and the OSS sensor.
41. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
42. Disconnect the upper radiator hose.
43. Detach the heater hose support strap from the stud.
44. Disconnect the heater hoses from the heater core.
45. Remove the retainers and the accelerator cable snow shield.
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.
47. Remove the nut from the accelerator control cable bracket.
48. Remove the nut from the accelerator control cable bracket. Position the accelerator control cable and bracket assembly aside.
49. Disconnect the vacuum supply tube and position aside.
50. Disconnect the fuel vapor return tube and retainer and position aside.
51. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
52. Detach the electrical connector retainers.
53. Remove the bolt and detach the ground wire.
54. Disconnect the PCM electrical connectors. Remove the wiring harness retainer nut.
55. Disconnect the lower radiator hose from the radiator.
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.
57. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
58. Remove the rear nut and the engine support crossmember. Discard the nut.
59. Remove the 3 bolts and the damper.
60. Remove the 2 transaxle-to-engine bolts.
61. Remove the 2 transaxle-to-engine bolts.
62. Using the special tools, secure the engine to the lift table.
63. Remove the engine mount bracket bolt.
64. Remove the nuts and the engine mount bracket.
65. Remove the bolt from the transaxle rear mount.
66. Remove the bolt from the LH transaxle mount.
67. Lower the engine and transaxle from the vehicle.
68. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
69. Remove the wire harness clip retainer and the ground wire from the starter bolts.
70. Remove the 2 stud bolts and remove the starter.
71. Remove the starter motor isolator.
72. Remove the 2 lower catalytic converter bolts.
73. Remove the 6 bolts and the catalytic converter heat shield.
74. Remove and discard the 7 exhaust manifold nuts.
75. Remove the catalytic converter and discard the exhaust manifold gasket.
76. Remove and discard the 7 exhaust manifold studs.
77. Remove the 3 PTU bracket-to-engine bolts.
78. Remove the 2 PTU bracket-to-PTU bolts and remove the bracket.
79. Detach the PTU vent hose retainer.
80. Remove the transaxle-to-PTU bolt.
81. Remove the 3 PTU-to-transaxle bolts and the PTU.
82. Remove and discard the 4 torque converter nuts.
83. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
84. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.

Engine - Manual Transaxle

Special Tools Illustration Tool Name Tool Number Front Drive Halfshaft Remover 205-241 (T86P-3514-A) Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Tie-Rod End Remover 211-105 (T85M-3395-A) Universal Adapter Brackets 014-0001

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
3. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
4. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
5. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
6. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.
8. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
9. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
10. Remove the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
11. Press the 2 locking tabs (1 shown) to release the lower air duct from the upper air duct.
12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer. Remove the generator shield.
13. Remove the 4 bolts and the lateral support crossmember.
14. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
15. Disconnect the LH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
16. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
17. Disconnect the RH suspension. Disconnect the stabilizer bar link. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
18. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
19. Separate the LH and RH lower control arms and disconnect the steering knuckle from the lower ball joint and position the steering knuckle aside.
20. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
21. Using the special tools, remove the RH halfshaft from the intermediate shaft and secure the halfshaft aside.
22. Remove the 2 intermediate shaft retaining nuts.
23. Remove the intermediate shaft.
24. Remove the power distribution box (PDB) cover.
25. Remove the nut and the cable from the PDB.
26. Disconnect the electrical connector from the PDB.
27. Remove the bolt and ground strap.
28. Disconnect the 34-pin electrical connector.
29. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness aside.
30. 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.
31. Remove the wiring harness bracket nut and position aside
32. Disconnect the vehicle speed sensor (VSS) electrical connector and pin-type retainers.
33. Disconnect the reversing lamp indicator switch.
34. Disconnect the shift cables.
35. Remove the 3 shift cable bracket bolts. Position the bracket aside.
36. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
37. Disconnect the upper radiator hose.
38. Detach the heater hose support strap from the stud.
39. Disconnect the heater hoses from the heater core.
40. Remove the retainers and the accelerator cable snow shield.
41. 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.
42. Remove the nut from the accelerator control cable bracket. Position the accelerator control cable and bracket assembly aside.
43. Remove the nut from the accelerator control cable bracket.
44. Disconnect the vacuum supply tube and position aside.
45. Disconnect the fuel vapor return tube and position aside.
46. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
47. Detach the electrical connector retainers.
48. Remove the bolt and detach the ground wire.
49. Disconnect the PCM electrical connectors. Remove the wiring harness retainer nut.
50. Disconnect the lower radiator hose from the radiator.
51. 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.
52. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
53. Remove the rear nut and the engine support crossmember. Discard the nut.
54. Remove the 2 transaxle-to-engine bolts.
55. Remove the 2 engine-to-transaxle bolts.
56. Using the special tools, secure the engine to the lift table.
57. Remove the engine mount bracket bolt.
58. Remove the nuts and the engine mount bracket.
59. Remove the bolt from the transaxle rear mount.
60. Remove bolt from the LH transaxle mount.
61. Lower the engine and transaxle from the vehicle.
62. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
63. Remove the wire harness clip retainer and the ground wire from the starter bolts.
64. Remove the 2 stud bolts and remove the starter.
65. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
66. Remove the remaining 5 engine-to-transaxle bolts and separate the engine and transaxle.

Special Tools Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-00232 or equivalent Heavy Duty Floor Crane 014-00071 or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft 303-507

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

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

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

Note. For additional information, refer to the exploded views under the engine assembly procedure in this article.

Vehicles with manual transaxle

1. Remove the bolts, clutch pressure plate and clutch disc.
2. Remove the starter motor isolator.
3. Remove the bolts and the flywheel.
4. Remove the bolts and the flexplate.
5. Mount the engine on a suitable stand.
6. Disconnect the crankshaft position (CKP) sensor electrical connector.
7. Remove the nut and disconnect the generator electrical connections.
8. Remove the 2 lower catalytic converter bolts.
9. Remove the 6 heat shield bolts and the heat shield.
10. Remove and discard the 7 exhaust manifold nuts.
11. Remove the catalytic converter and discard the exhaust manifold gasket.
12. Remove and discard the 7 exhaust manifold studs.
13. Remove the nut, bolts and the generator.
14. Loosen the bolt and remove the accessory drive belt idler pulley.
15. Remove the 3 bolts and the accessory drive belt idler pulley and bracket.
16. Remove the bolts and the coolant pump pulley.
17. Remove the bolts and the coolant pump.
18. Detach the 2 wiring harness retainers.
19. Remove the 3 bolts and the thermostat housing assembly.
20. Remove the bolt and the oil level indicator.
21. Disconnect the engine oil pressure (EOP) switch electrical connector.
22. Remove the engine oil filter.
23. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
24. If equipped, remove the bolt and capacitor.
25. Detach the 2 wiring harness retainers.
26. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
27. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
28. Disconnect the idle air control (IAC) motor electrical connector.
29. Disconnect the swirl control valve electrical connector.
30. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
31. Disconnect the radio capacitor electrical connector.
32. Disconnect the throttle position (TP) sensor electrical connector.
33. Remove the bolts and position the intake manifold aside.
34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
35. Remove the EGR tube.
36. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
37. Remove the nut and the radio capacitor.
38. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
39. Detach the wiring harness retainer.
40. Disconnect the EGR valve electrical connectors. Detach the wiring harness retainer.
41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
42. Detach the wiring harness retainer.
43. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
44. Disconnect the coolant hose.
45. Disconnect and remove the coolant hose.
46. Disconnect and remove the coolant hoses.
47. Remove the bolt and the KS.
48. Remove the bolts and the crankcase vent oil separator.
49. If equipped, remove the block heater.
50. Remove the crankcase vent tube and the coil-on-plugs.
51. Remove the spark plugs and the CHT sensor. Discard the CHT.
52. Remove the bolts and the valve cover.
53. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
54. Install the special tool in the slots on the rear of both camshafts.
55. Remove the engine plug bolt.
56. Install the special tool.
57. Assemble the special tools using 4 hardened washers in the locations shown.
58. Using the special tools and an air impact wrench, remove the crankshaft pulley. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
59. Using the special tool, remove the crankshaft front oil seal.
60. Remove and discard the CKP sensor.
61. Remove the bolts and the engine front cover.
62. Remove the timing chain tensioner. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner. Remove the bolts and timing chain tensioner.
63. Remove the RH timing chain guide.
64. Remove the timing chain.
65. Remove the bolts and the LH timing chain guide.
66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
67. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
68. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
70. Remove the camshafts from the engine. Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.
71. Remove the cylinder head. Remove and discard the cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
72. Remove the cylinder head alignment dowels.
73. Remove the bolts and the oil pan.
74. Remove the bolts and the rear crankshaft seal.
75. Remove the bolts, oil pump pickup tube and gasket.
76. Remove the bolts and the oil pump.