Engine - 2.3L: Removal & Installation Mercury Milan I

REMOVAL AND INSTALLATION

All vehicles

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-271065) .
4. Remove the bolt, 2 nuts and the generator air inlet duct. To install, tighten to 6 Nm (53 lb-in).
5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
7. Disconnect the 2 swirl control valve electrical connectors.
8. Detach the 2 wiring harness pin-type retainers and remove the fuel rail insulator.
9. Detach the electrical connector pin-type retainer.
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
12. Disconnect the AIR pump electrical connector.
13. Remove the 3 bolts and position the AIR pump aside. To install, tighten to 30 Nm (22 lb-ft).
14. Disconnect the vacuum hose from the intake manifold.
15. Detach the radiator hose retaining clip from the intake manifold.
16. Remove the intake manifold lower bolt. To install, tighten to 18 Nm (13 lb-ft).
17. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
18. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
19. Disconnect the oil pressure sender electrical connector. Detach the wiring harness pin-type retainer and position the wiring harness aside.
20. Remove the nut and the S-terminal wire from the starter. To install, tighten to 12 Nm (9 lb-ft).
21. Disconnect the throttle body electrical connector.
22. Remove the 4 bolts and position the throttle body aside. To install, tighten to 10 Nm (89 lb-in).
23. Detach the 2 pin-type retainers from the intake manifold.
24. Remove the 7 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).
25. Release the clamp and disconnect the crankcase vent hose.
26. Detach the knock sensor (KS) electrical connector pin-type retainer.
27. Remove the exhaust gas recirculation (EGR) tube. To install, tighten to 55 Nm (41 lb-ft).
28. Remove the intake manifold and discard the gaskets. To install, tighten to 18 Nm (13 lb-ft).
29. To install, reverse the removal procedure. Install new throttle body and intake manifold gaskets.

REMOVAL

1. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-271126) .
2. Remove the engine wiring harness bracket from the valve cover stud.
3. Remove the oil level indicator.
4. Disconnect the crankcase vent hose.
5. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
6. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
7. Disconnect the camshaft position (CMP) sensor electrical connector.
8. Detach all of the wiring harness retainers from the valve cover and the valve cover studs.
9. Remove the 14 valve cover retainers and the valve cover. Discard the gasket.

INSTALLATION

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown.
3. Install the valve cover, new gasket and retainers. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the wiring harness and attach all of the wiring harness retainers to the valve cover and the valve cover studs.
5. Connect the CMP sensor electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the VCT solenoid electrical connector.
8. Connect the crankcase vent hose.
9. Install the oil level indicator.
10. Position the engine wiring harness bracket on the valve cover stud.
11. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-271126) .

Scheme 1

1. For additional information, refer to the appropriate procedures.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-271072-S36168339522007110800000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at 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 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
8. Remove the engine plug bolt.
9. Install the special tool.
10. Assemble the special tools using 4 hardened washers in the locations shown.
11. 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.

All vehicles

1. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
2. 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.
3. Assemble the special tools using 4 hardened washers in the locations shown.
4. 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).
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 clockwise 1 and 3/4 turns.
9. Install the special tool.
10. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
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.
12. Using the special tool, 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. To install, tighten to 20 Nm (15 lb-ft).
17. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
18. If equipped, install the underbody cover and the 7 screws.
19. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
20. Install the valve cover. For additional information, refer to «Valve Cover»(ref-271072-S36168339522007110800000) .

1. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-271072-S10827585162007110800000) .
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 «Crankshaft Pulley»(ref-271072-S10827585162007110800000) .

Scheme 2

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the automatic transaxle. For additional information, refer to the appropriate «AUTOMATIC TRANSAXLE/TRANSMISSION - 6 SPEED»(ref-271076) or «AUTOMATIC TRANSAXLE/TRANSMISSION - FNR5»(ref-271121) .
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 the appropriate «AUTOMATIC TRANSAXLE/TRANSMISSION - 6 SPEED»(ref-271076) or «AUTOMATIC TRANSAXLE/TRANSMISSION - FNR5»(ref-271121) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the clutch. For additional information, refer to «CLUTCH»(ref-271087) .
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-271087) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-271072-S05959433252007110800000) or «Flywheel»(ref-271072-S12562184812007110800000) .
3. Remove the 17 bolts and the oil pan.
4. 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, engine front cover 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 20 Nm (15 lb-ft).
7. Install the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-271072-S05959433252007110800000) or «Flywheel»(ref-271072-S12562184812007110800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the accessory drive belt and idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
4. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-271072-S10827585162007110800000) .
5. If equipped, remove the 7 screws and the underbody cover.
6. Remove the engine mount. For additional information, refer to «Engine Mount»(ref-271072-S23713206582007110800000) .
7. Using the special tool, remove and discard the crankshaft front oil seal.
8. Remove the 3 bolts and the coolant pump pulley.
9. Disconnect the power steering pressure (PSP) switch electrical connector.
10. Remove the 3 power steering pump bolts and position the power steering pump aside.
11. Disconnect the crankshaft position (CKP) sensor electrical connector.
12. Remove the 2 bolts and the CKP sensor. Discard the CKP sensor.
13. Remove the 22 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. Position the power steering pump and install the 3 bolts.
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-271072-S23713206582007110800000) .
8. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-271072-S10827585162007110800000) .
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. Do not tighten the bolts at this time.
11. Adjust the new CKP sensor with the alignment tool. Tighten the 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. If equipped, install the underbody cover and the 7 screws.
15. Install the accessory drive belt and idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
16. Tighten the 3 coolant pump pulley bolts to 20 Nm (15 lb-ft).

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271072-S31701266222007110800000) .
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.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.

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 Nm (89 lb-in).
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 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-271072-S31701266222007110800000) .

Scheme 3

1. Remove the variable camshaft timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-271070) .
2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. To install, tighten to 17 Nm (13 lb-ft).
3. To install, reverse the removal procedure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the variable camshaft timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-271070) .
5. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-271072-S02542789552007110800000) .
6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
7. Install the special tool in the slots on the rear of both camshafts.
8. Remove the 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
9. Remove the engine plug bolt.
10. Install the special tool.
11. 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.
12. Remove the lower timing hole plug from the engine front cover.
13. Remove the upper timing hole plug from the engine front cover.
14. Reposition the special tool to the slot on the rear of the intake camshaft only.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
17. Remove the special tool.
18. Remove the timing chain from the intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in the sequence shown, 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.
21. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

All vehicles

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 Nm (53 lb-ft).
2. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
3. Install the special tool.
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 (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt 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 timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (9 lb-ft).
13. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
14. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
15. If equipped, install the underbody cover and the 7 screws.
16. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
17. Install the variable camshaft timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-271070) .

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the variable camshaft timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-271070) .
5. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-271072-S02542789552007110800000) .
6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
7. Install the special tool in the slots on the rear of both camshafts.
8. Remove the 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
9. Remove the engine plug bolt.
10. Install the special tool.
11. 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.
12. Remove the lower timing hole plug from the engine front cover.
13. Remove the upper timing hole plug from the engine front cover.
14. Reposition the special tool to the slot on the rear of the intake camshaft only.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
17. Remove the special tool.
18. Remove the timing chain from the intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the intake camshaft from the engine. Loosen the intake camshaft bearing cap bolts, in the sequence shown, 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 intake camshaft.
21. Mark the camshaft phaser and sprocket and the camshaft for reference during installation.
22. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

All vehicles

1. Position the camshaft in a soft-jawed vise. 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 Nm (53 lb-ft).
2. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence shown in 3 stages: Stage 1: Tighten the intake camshaft bearing cap bolts until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
3. Install the special tool.
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 (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt 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 timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (9 lb-ft).
13. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
14. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts. Tighten to 40 Nm (30 lb-ft).
15. If equipped, install the underbody cover and the 7 screws.
16. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-271084) .
17. Install the variable camshaft timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-271070) .

Scheme 4

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-271072-S07343365252007110800000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-271126) .
5. Connect compressed air supply to the No. 1 cylinder.
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 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 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-271126) .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «Camshafts»(ref-271072-S07343365252007110800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-271072-S07343365252007110800000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.3L»(ref-271126) .
5. Connect compressed air supply to the No. 1 cylinder.
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 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 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-271126) .
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «Camshafts»(ref-271072-S07343365252007110800000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the camshafts. For additional information, refer to «Camshafts»(ref-271072-S07343365252007110800000) .
3. Remove and inspect the valve tappets. For additional information refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
3. Check the valve clearance. For additional information, refer to «Valve Clearance Check»(ref-271072-S02542789552007110800000) .
4. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-271067) .
5. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-271069) .
6. Remove the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-271068) .
7. Remove the fuel supply rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-271078) .
8. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-271072-S17466066882007110800000) .
9. Disconnect the secondary air injection (AIR) pump electrical connector.
10. Remove the 3 bolts and position the AIR pump aside.
11. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
12. Remove the engine mount bracket bolt.
13. Install the special tool and a suitable length of chain to the threaded hole in the LH side of the engine block.
14. Install the special. Using the special tool, lift the engine 25 mm (0.98 in).
15. Remove the nut, 2 bolts and the engine mount.
16. Lower the engine 25 mm (0.98 in).
17. Remove the 2 nuts and the engine mount bracket.
18. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(ref-271072-S13135902002007110800000) .
19. Remove the special tool.
20. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
21. Remove the bolt and the variable camshaft timing (VCT) solenoid.
22. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in the sequence shown, 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.
23. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
24. Detach the retaining clip and position the evaporative emissions (EVAP) tube bundle aside.
25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
26. Disconnect the engine coolant temperature sensor (ECT) electrical connector.
27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
29. Remove the 2 bolts and position AIR valve bracket aside.
30. Remove the 10 bolts and the cylinder head. Discard the bolts.

All vehicles

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. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new head gasket.
6. Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 7 Nm (62 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. Position AIR valve bracket and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Connect the coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Connect the ECT electrical connector.
11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
12. Attach the EVAP tube bundle retaining clip retaining clip.
13. Install the valve tappets.
14. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages: Stages 1: Tighten the camshaft bearing cap bolts until finger tight. Stages 2: Tighten to 7 Nm (62 lb-in). Stages 3: Tighten to 16 Nm (12 lb-ft).
15. Install the special tool.
16. Install the VCT solenoid and bolt. Tighten to 10 Nm (89 lb-in).
17. Install the timing drive components. For additional information, refer to «Timing Drive Components»(ref-271072-S13135902002007110800000) .
18. Install the engine mount bracket and the 2 nuts. Tighten to 103 Nm (76 lb-ft).
19. Using the special too, lift the engine 25 mm (0.98 in).
20. Install the engine mount, nut and 2 bolts. Tighten to 55 Nm (41 lb-ft).
21. Lower the engine 25 mm (0.98 in).
22. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
23. Install the radio frequency interference capacitor and bolt to the engine mount bracket. Tighten to 10 Nm (89 lb-in).
24. Install the AIR pump and the 3 bolts. Tighten to 30 Nm (22 lb-ft).
25. Connect the AIR pump electrical connector.
26. Install the intake manifold. For additional information, refer to «Intake Manifold»(ref-271072-S17466066882007110800000) .
27. Install the fuel supply rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-271078) .
28. Install the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-271068) .
29. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-271069) .
30. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-271067) .
31. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-271067) .

Scheme 5

Note. Automatic transmission shown, manual transmission similar.

Scheme 6

Scheme 7

Scheme 8

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. If equipped, remove the 2 screws and the oil filter access cover.
3. Loosen the oil filter drain plug.
4. Using a cup-style oil filter wrench, loosen the oil filter cover one turn.
5. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter. Remove and discard the oil filter drain plug O-ring seal.
6. Remove the oil filter cover and oil filter element. Discard the oil filter element. Remove and discard the oil filter cover O-ring seal.

1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter.
2. Install a new oil filter cover O-ring seal.
3. Install a new oil filter element and the oil filter cover. Using a cup-style oil filter wrench, tighten to 33 Nm (24 lb-ft).
4. Install a new oil filter drain plug O-ring seal.
5. Install the oil filter drain plug. Tighten to 10 Nm (89 lb-in).
6. If equipped, install the oil filter access cover and the 2 screws.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. If equipped, remove the 7 screws and the underbody cover.
3. Remove the oil filter element. For additional information, refer to «Oil Filter Element»(ref-271072-S30603108202007110800000) .
4. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
5. Disconnect the AIR pump electrical connector.
6. Remove the 3 bolts and position the AIR pump aside. To install, tighten to 30 Nm (22 lb-ft).
7. Disconnect the oil pressure sender electrical connector.
8. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
9. To install, reverse the removal procedure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. If equipped, remove the 7 screws and the underbody cover.
3. Remove the 2 bolts and position the clutch slave cylinder aside. To install, tighten to 22 Nm (16 lb-ft).
4. Disconnect the oil pressure sender electrical connector.
5. Remove the oil pressure sender. To install, tighten to 15 Nm (11 lb-ft).
6. To install, reverse the removal procedure. Apply pipe sealant with Teflon® to the oil pressure sender threads.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-271065) .
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
4. Loosen the 3 upper transaxle-to-engine bolts 5 mm (0.19 in).
5. If equipped, remove the 7 screws and the underbody cover.
6. Loosen the 1 (automatic transmission) or 2 (manual transmission) front lower bellhousing-to-engine bolt(s) 5 mm (0.19 in).
7. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Remove the bellhousing-to-oil pan bolt.
10. Slide the transmission rearward 5 mm (0.19 in).
11. Drain the engine oil. Install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
12. Remove the 4 engine front cover-to-oil pan bolts.
13. 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 transmission and engine together. Tighten to 48 Nm (35 lb-ft).
7. Tighten the remaining front lower bolt (manual transmission) and rear lower stud bolt. Tighten to 48 Nm (35 lb-ft).
8. Install the bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
9. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
10. If equipped, install the underbody cover and the 7 screws.
11. Tighten the 3 top bellhousing-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
13. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-271065) .
14. 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-271051) .
2. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-271072-S39918976532007110800000) and «Oil Pan»(ref-271072-S39611582442007110800000) .
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.

Note. Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

All vehicles

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271072-S31701266222007110800000) .
3. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 3 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. To install, tighten to 10 Nm (89 lb-in).
7. Remove the oil pump drive chain tensioner and guide. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner. Remove the 2 shoulder bolts and the guide.
8. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
9. Remove the chain from the oil pump sprocket.
10. Remove the bolt and oil pump sprocket.
11. Remove the 4 bolts and the oil pump.

All vehicles

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 (15 lb-ft).
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 guide and the shoulder bolts. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
7. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Clean all mating surfaces with metal surface cleaner.
9. 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.
10. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
11. Install the remaining oil pan bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
12. Install the 3 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271072-S31701266222007110800000) .
14. 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-271051) .
2. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-271067) .
3. Install the special tool. Attach the special tool to the front and rear engine lifting eyes.
4. Remove the bolt and the radio frequency interference capacitor. To install, tighten to 10 Nm (89 lb-in).
5. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
6. Use the special tool to raise the engine 25 mm (0.98 in).
7. Remove the 2 engine mount bracket nuts. To install, tighten to 103 Nm (76 lb-ft).
8. Remove the nut, 2 bolts and the engine mount. To install, tighten to 55 Nm (41 lb-ft).
9. Use the special tool to lower the engine 25 mm (0.98 in). Remove the engine mount bracket.
10. To install, reverse the removal procedure.

Engine - Automatic Transaxle

Special Tools Illustration Tool Name Tool Number Separator, Ball joint 205-592 Adapter for 204-592 204-592/1 Tie-Rod End Remover 211-105 Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
4. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-271114)
5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
6. Remove the 2 nuts and the steering joint cover.
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump. Route the PSP tube out the bottom of the engine compartment.
9. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-271067) .
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-271069) .
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
13. Remove the engine roll restrictor bolt.
14. Remove the 4 screws and position the RH fender splash shield aside.
15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
16. Remove the 4 screws and position the LH fender splash shield aside.
17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
18. Remove the cotter pins and nuts from the tie-rod ends.
19. Using the special tool, separate the tie-rod ends from the steering knuckles.
20. Disconnect the power steering cooler tube.
21. Remove the nuts and separate the sway bar links from the struts.
22. Remove the lower ball joint nuts.
23. Using the special tools, separate the lower ball joints from the lower control arms.
24. Remove the through bolts from the lower control arms.
25. Position the special tool under the subframe assembly.
26. Remove the subframe bracket-to-body bolts.
27. Remove the subframe nuts and the subframe brackets.
28. Remove the front subframe nuts.
29. Lower the subframe assembly from the vehicle.
30. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
31. Remove the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-271072-S39918976532007110800000) and «Oil Filter Element»(ref-271072-S30603108202007110800000) .
32. Remove the bolt, 2 nuts and the generator air inlet duct.
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-271065) .
34. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
35. Remove the nut and disconnect the wire from the battery cable.
36. Disconnect the 2 engine wiring harness electrical connectors.
37. Remove the bolt and the ground wire.
38. Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
40. Disconnect the crankcase vent tube from the valve cover.
41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
42. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
43. Detach the retaining clip and position the EVAP tube bundle aside.
44. Disconnect the upper radiator and heater hoses from the coolant bypass.
45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
46. Disconnect the heater hose inline connector.
47. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
48. Disconnect the transaxle cooler tubes.
49. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
50. Detach the coolant vent hose retaining clip from the A/C tube.
51. Disconnect the power steering cooler tube.
52. Remove the 2 A/C tube bracket bolts.
53. Remove the 2 nuts and disconnect the A/C tubes.
54. Remove the nut and disconnect the A/C tube from the condenser.
55. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
56. Remove the retaining clip and disconnect the lower radiator hose.
57. Using a suitable tool, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
58. Remove the 2 RH halfshaft carrier bearing bracket bolts.
59. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
60. Remove the bellhousing-to-oil pan bolt.
61. Remove the 2 oil pan-to-bellhousing bolts.
62. Disconnect the AIR pump electrical connector.
63. Remove the 3 bolts and position the AIR pump aside.
64. Install the special tools onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
65. Remove the 2 transaxle mount bolts.
66. Remove the bolt, 2 nuts and the engine mount bracket.
67. Lower the engine and transaxle from the vehicle.
68. Remove the 2 nuts and disconnect the starter wires.
69. Detach the 2 wiring harness retainers from the starter stud bolts.
70. Remove the 2 stud bolts and the starter.
71. Remove the 4 torque convertor nuts.
72. Remove the bolt and ground wire.
73. Remove the nut and position the engine wiring harness bracket aside.
74. Disconnect the transmission range (TR) sensor and primary control solenoid electrical connectors.
75. Disconnect the transaxle control electrical connectors.
76. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
77. Disconnect the output shaft speed (OSS) sensor electrical connector.
78. Disconnect the transaxle pressure switch electrical connector.
79. Install the special tools and remove the engine and transaxle from the powertrain lift table.
80. Remove the bellhousing-to-engine retainers. Separate the engine and transaxle.

Engine - Manual Transaxle

Special Tools Illustration Tool Name Tool Number Separator, Ball joint 205-592 Adapter for 204-592 204-592/1 Tie-Rod End Remover 211-105 Remover, Halfshaft 205-832 Slide Hammer 100-001 Remover, Halfshaft 205-243 Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Scheme 16

Scheme 17

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
4. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-271114)
5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
6. Remove the 2 nuts and the steering joint cover.
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump. Route the PSP tube out the bottom of the engine compartment.
9. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-271067) .
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-271069) .
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
13. Remove the engine roll restrictor bolt.
14. Remove the 4 screws and position the RH fender splash shield aside.
15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
16. Remove the 4 screws and position the LH fender splash shield aside.
17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
18. Remove the cotter pins and nuts from the tie-rod ends.
19. Using the special tool, separate the tie-rod ends from the steering knuckles.
20. Disconnect the power steering cooler tube.
21. Remove the nuts and separate the sway bar links from the struts.
22. Remove the lower ball joint nuts.
23. Using the special tools, separate the lower ball joints from the lower control arms.
24. Remove the through bolts from the lower control arms.
25. Position the special tool under the subframe assembly.
26. Remove the subframe bracket-to-body bolts.
27. Remove the rear subframe nuts and the subframe brackets.
28. Remove the front subframe nuts.
29. Lower the subframe assembly from the vehicle.
30. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 26 Nm (19 lb-ft).
31. Remove the oil filter element. For additional information, refer to «Engine Lubrication Components - Exploded View»(ref-271072-S39918976532007110800000) and «Oil Filter Element»(ref-271072-S30603108202007110800000) .
32. Remove the bolt, 2 nuts and the generator air inlet duct.
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-271065) .
34. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
35. Remove the nut and disconnect the wire from the battery cable.
36. Disconnect the 2 engine wiring harness electrical connectors.
37. Remove the bolt and the ground wire.
38. Disconnect the powertrain control module (PCM) electrical connector and pin-type retainer.
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
40. Disconnect the crankcase vent tube from the valve cover.
41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
42. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
43. Detach the retaining clip and position the EVAP tube bundle aside.
44. Disconnect the upper radiator and heater hoses from the coolant bypass.
45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
46. Disconnect the heater hose inline connector.
47. Remove the 2 clutch tube bracket bolts.
48. Remove the 2 bolts and position the clutch slave cylinder aside.
49. Disconnect the transaxle control cables from the control levers. Detach the control cables from the bracket.
50. Disconnect the power steering cooler tube.
51. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
52. Detach the coolant vent hose retaining clip from the A/C tube.
53. Remove the 2 A/C tube bracket bolts.
54. Remove the 2 nuts and disconnect the A/C tubes.
55. Remove the nut and disconnect the A/C tube from the condenser.
56. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
57. Remove the retaining clip and disconnect the lower radiator hose.
58. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
59. Remove the 2 RH halfshaft carrier bearing bracket bolts.
60. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
61. Remove the bellhousing-to-oil pan bolt.
62. Remove the 2 oil pan-to-bellhousing bolts.
63. Install the special tools onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
64. Remove the 2 transaxle mount bolts.
65. Remove the bolt, 2 nuts and the motor mount bracket.
66. Lower the engine and transaxle from the vehicle.
67. Remove the 2 nuts and disconnect the starter wires.
68. Detach the 2 wiring harness retainers from the starter stud bolts.
69. Remove the 2 bolts and the starter.
70. Remove the bolt and ground wire.
71. Remove the nut and position the engine wiring harness bracket aside.
72. Disconnect the backup lamp electrical connector.
73. Disconnect the vehicle speed sensor (VSS) electrical connector.
74. Install the special tools and remove the engine and transaxle from the powertrain lift table.
75. Remove the bellhousing-to-engine retainers. Separate the engine and transaxle.

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

Note. For additional information, refer to the exploded views under the Engine .

Note. Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

Vehicles with manual transaxle

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Remove the 6 bolts, clutch pressure plate and clutch disc.
2. Remove the starter motor isolator.
3. Remove the 6 bolts and the flywheel.
4. Remove the 6 bolts and the flexplate.
5. Mount the engine on a suitable stand.
6. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
7. Remove the accessory drive belt from the engine.
8. Remove the 2 bolts and the tensioner.
9. Disconnect the power steering pressure (PSP) switch electrical connector.
10. Remove the 2 upper power steering pump bolts.
11. Remove the lower bolt and the power steering pump.
12. Disconnect the knock sensor (KS) electrical connector and the 2 harness pin-type retainers.
13. Disconnect the lower radiator and heater hoses from the thermostat housing. Detach the radiator hose retainer clip from the intake manifold.
14. Disconnect the coolant hose from the throttle body and remove the hose from the engine.
15. Disconnect the A/C compressor electrical connector.
16. Remove the bolt and the A/C manifold.
17. Remove the 3 bolts and the A/C compressor.
18. Remove the 3 bolts and the coolant pump pulley.
19. Remove the 3 bolts and the coolant pump. Remove and discard the O-ring seal.
20. Remove the bolt and the accessory drive belt idler pulley.
21. Disconnect the crankshaft position (CKP) sensor electrical connector and harness pin-type retainer.
22. Remove the 2 bolts and the CKP sensor. Discard the CKP sensor.
23. Remove the 2 nuts and the generator splash shield.
24. Pull back the rubber boot and remove the nut. Disconnect the generator electrical connections and pin-type retainer.
25. Remove the bolt, 2 stud bolts and the generator.
26. Disconnect the secondary air injection (AIR) hose from the catalytic converter.
27. Disconnect the AIR valve vacuum supply tube from the intake manifold.
28. Disconnect the AIR valve electrical connector.
29. Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.
30. Disconnect the CMS electrical connector(s).
31. Disconnect the heated oxygen sensor (HO2S) electrical connector.
32. Remove the wiring harness bracket from the valve cover stud.
33. Detach the wiring harness retainer from the valve cover stud.
34. Remove the 6 screws and the heat shield.
35. Remove the 2 catalytic converter bracket bolts.
36. Remove the 7 nuts, catalytic converter, gasket and the 7 studs. Discard the nuts, gasket and the studs.
37. If equipped, disconnect the block heater electrical connector.
38. If equipped, remove the block heater.
39. Remove the 2 bolts and the catalytic converter bracket.
40. Disconnect the coolant temperature sender electrical connector.
41. Disconnect the exhaust gas recirculation (EGR) coolant hose and electrical connector.
42. Disconnect the oil pressure sender electrical connector.
43. Disconnect the manifold actual pressure (MAP) sensor electrical connector.
44. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
45. Disconnect the 2 swirl control valve electrical connectors.
46. Detach the 2 wiring harness pin-type retainers from the intake manifold.
47. Disconnect the electronic throttle body electrical connector.
48. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. Discard the gaskets.
49. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
50. Remove the EGR tube.
51. Remove the 3 bolts and the thermostat housing.
52. Disconnect the bypass hose from the cylinder block nipple.
53. Disconnect the bypass hose from the coolant outlet and remove the bypass hose from the engine.
54. Remove the bolt and the KS.
55. Remove the 8 bolts and the crankcase vent oil separator. Discard the gasket.
56. Remove and discard the engine oil filter.
57. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
58. Disconnect the camshaft position (CMP) sensor electrical connector.
59. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
60. Disconnect the 4 coil-on-plug electrical connectors.
61. Pull back the boot and disconnect the cylinder head temperature (CHT) sensor electrical connector.
62. Detach the 2 pin-type harness retainers and remove the fuel supply rail insulator.
63. Disconnect the 4 fuel injector electrical connectors.
64. Detach the remaining wiring harness retainers and remove the wiring harness from the engine.
65. Remove the 2 bolts and the fuel rail and injector assembly.
66. Remove the 4 bolts and the 4 coil-on-plug assemblies.
67. Remove the oil level indicator.
68. Loosen the 14 retainers and remove the valve cover. Discard the gaskets.
69. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
70. Install the special tool in the slots on the rear of both camshafts.
71. Remove the engine plug bolt.
72. Install the special tool.
73. Assemble the special tools using 4 hardened washers in the locations shown.
74. 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.
75. Using the special tool, remove the crankshaft front oil seal.
76. Remove the 22 bolts and the engine front cover.
77. 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.
78. Remove the RH timing chain guide.
79. Remove the timing chain.
80. Remove the 2 bolts and the LH timing chain guide.
81. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
82. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
83. Remove the oil pump drive chain tensioner and guide. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner. Remove the 2 shoulder bolts and the guide.
84. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
85. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
86. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
87. Remove the bolt and the VCT solenoid.
88. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in the sequence shown, 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.
89. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075).
90. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
91. Remove the 2 cylinder head alignment dowels.
92. Remove the 13 bolts and the oil pan.
93. Remove the 6 bolts and the rear crankshaft seal.
94. Remove the 2 bolts, oil pump pickup tube and gasket.
95. Remove the 4 bolts and the oil pump.
96. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center (TDC). Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. see scheme 414: Installing Crankshaft TDC Timing Peg
97. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. see scheme 415: Locating Balancer Unit And Shafts Reference Mark
98. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. see scheme 416: Locating Balancer Unit Bolts
99. Remove the Crankshaft TDC Timing Peg. see scheme 417: Installing Crankshaft TDC Timing Peg
100. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
101. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly. Remove the connecting rod cap bolts and cap. see scheme 418: Locating Connecting Rod Cap Bolts
102. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block. see scheme 419: Identifying Connecting Rod Installer
103. Remove the bolts in the sequence shown. Remove the main bearing beam. Discard the bolts. see scheme 420: Identifying Crankshaft Cap Bolts Removing Sequence
104. Remove the crankshaft from the engine block. see scheme 421: Locating Crankshaft
105. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. Remove the main bearings from the main bearing beam. see scheme 422: Locating Main Bearings
106. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing. Remove the main bearings from the cylinder block. see scheme 423: Locating Main Bearings
107. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter. Remove the 4 oil squirters. see scheme 424: Locating Oil Squirters
108. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075).