Engine: Removal & Installation Mercury Montego III

Removal

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-233003) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
4. Remove the 4 transaxle roll restrictor cross brace bolts.
5. Remove the bolt and the transaxle roll restrictor cross brace.
6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer.
7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold.
8. Detach the fuel tube retainer from the upper intake manifold.
9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube.
10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer.
11. Disconnect the EGR system module tube from the EGR system module.
12. Disconnect and plug the throttle body and PCV coolant hoses.
13. Disconnect the throttle body electrical connector.
14. If equipped, remove and discard the 4 upper-to-lower intake manifold screws.
15. Remove the 8 bolts and the upper intake manifold. Remove and discard the gaskets.

Scheme 1

1. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Connect the throttle body electrical connector.
3. Connect the throttle body and PCV coolant hoses.
4. Connect the EGR system module tube to the EGR system module. Tighten to 40 Nm (30 lb-ft).
5. Attach the vacuum tube to the upper intake manifold vacuum tube retainer.
6. Connect the EGR system module electrical connector and vacuum tube.
7. Attach the fuel tube retainer to the upper intake manifold.
8. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
9. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer.
10. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
11. Position the transaxle roll restrictor cross brace and install the 4 new bolts. Tighten to 55 Nm (41 lb-ft).
12. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
13. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
14. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
16. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-233003) .

Scheme 2

Scheme 3

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233044) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233006-S19785561622006052400000) .
4. Disconnect the fuel tube redundant clip.
5. Press the fuel tube quick release coupling button and disconnect the fuel tube from the fuel rail.
6. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
7. Disconnect the fuel charging wiring harness electrical connector.
8. Remove the lower intake manifold. Remove and discard the gaskets.

Scheme 4

1. Position the lower intake manifold.
2. Connect the fuel charging wiring harness electrical connector.
3. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
4. Connect the fuel tube to the fuel rail.
5. Connect the fuel tube redundant clip.
6. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233006-S19785561622006052400000) .
7. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .

1. Remove the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(ref-233045) .
2. Disconnect the crankcase ventilation tube from the valve cover.
3. Remove the 3 nuts and position the wiring conduit aside.
4. Detach the 3 wiring retainers from the valve cover stud bolts.
5. Remove the oil level indicator.
6. Remove the 6 bolts, 8 stud bolts and the valve cover. Remove and discard the gasket.

Scheme 5

1. Clean the valve cover, cylinder head and front cover sealing surfaces.
2. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Position the valve cover and install the 6 bolts and 8 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Install the oil level indicator.
5. Attach the wiring retainers to the valve cover stud bolts.
6. Position the wiring conduit and install the 3 nuts. Tighten to 6 Nm (53 lb-in).
7. Attach the crankcase ventilation tube to the valve cover.
8. Install the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(ref-233045) .

1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233006-S19785561622006052400000) .
2. Remove the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(ref-233045) .
3. If equipped, disconnect the positive crankcase ventilation (PCV) valve electrical connector.
4. Remove the PCV tube.
5. Remove the 2 nuts and position the power steering fluid reservoir aside.
6. Remove the bolt and detach the power steering pressure (PSP) tube bracket from the fluid reservoir bracket.
7. Remove the nut and the power steering fluid reservoir bracket.
8. Remove the 3 power steering fluid reservoir bracket stud bolts from the valve cover.
9. Remove the bolt and detach the PSP tube bracket from the backside of the RH cylinder head.
10. Remove the 3 nuts and detach the wiring conduit from the valve cover stud bolts.
11. Detach the 2 wiring retainers from the valve cover stud bolts.
12. Remove the 9 bolts, 5 stud bolts and the RH valve cover. Remove and discard the gasket.

Scheme 6

1. Clean the valve cover, cylinder head and front cover sealing surfaces.
2. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Position the valve cover and install the 9 bolts and 5 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Attach the 2 wiring retainers to the valve cover stud bolts.
5. Attach the wiring conduit to the valve cover stud bolts and install the 3 nuts. Tighten to 6 Nm (53 lb-in).
6. Position the PSP tube bracket to the backside of the RH cylinder head and install the bolt. Tighten to 7 Nm (62 lb-in).
7. Install the 3 power steering fluid reservoir bracket stud bolts into the valve cover. Tighten to 7 Nm (62 lb-in).
8. Position the power steering fluid reservoir bracket and install the nut. Tighten to 9 Nm (80 lb-in).
9. Position the PSP tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
10. Position the power steering fluid reservoir and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
11. Install the PCV tube.
12. If equipped, connect the PCV valve electrical connector.
13. Install the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(ref-233045) .
14. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-233006-S19785561622006052400000) .

Scheme 7

Scheme 8

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

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-233006-S30162846032006052400000) .
2. Using the special tool, remove the crankshaft front oil seal and discard.

Scheme 9

1. Apply clean engine oil to the seal lip and seal bore before installing the seal.
2. Using the special tools, install the crankshaft front oil seal.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-233006-S30162846032006052400000) .

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - CVT»(ref-233028) or «AUTOMATIC TRANSAXLE - 6 SPEED»(ref-233010) .
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

Installation

1. Using the special tools, install the crankshaft rear oil seal.

Scheme 10

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Remove the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-233006-S05866754652006052400000) and «CRANKSHAFT FRONT SEAL»(ref-233006-S02414237342006052400000) .
4. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-233006-S24589360122006052400000) and «VALVE COVER - RH»(ref-233006-S03276844262006052400000) .
5. Remove the bolt and the accessory drive belt tensioner.
6. Remove the 3 power steering pump nuts and position the power steering pump and fluid reservoir aside.
7. Disconnect the crankshaft position (CKP) sensor electrical connector.
8. Disconnect the camshaft position (CMP) sensor electrical connector.
9. Remove the 2 generator-to-engine front cover stud nuts.
10. Remove the 2 generator-to-engine front cover studs.
11. Remove the 3 pin-type retainers and the radiator splash shield.
12. Remove the 2 A/C compressor bolts and the 2 A/C compressor nuts. Support the A/C compressor with mechanic's wire.
13. Remove the 2 A/C compressor bracket-to-engine front cover bolts.
14. Remove the nut and detach the ground wire from the engine front cover stud bolt.
15. Remove the 2 oil pan-to-front cover bolts.
16. Remove the 15 bolts, stud bolt and the engine front cover. Remove and discard the gaskets.

Scheme 11

1. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with silicone gasket remover and metal surface prep.
2. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
3. Position the engine front cover and install the 15 bolts and stud bolt. Tighten in the sequence shown to 25 Nm (18 lb-ft).
4. Install the 2 oil pan-to-front cover bolts. Tighten to 25 Nm (18 lb-ft).
5. Remove the oil pan plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
6. Attach the ground wire to the engine front cover stud bolt and install the nut. Tighten to 20 Nm (15 lb-ft).
7. Install the 2 A/C compressor bracket-to-engine front cover bolts. Tighten to 25 Nm (18 lb-ft).
8. Position the A/C compressor and install the 2 bolts and 2 nuts. Tighten to 25 Nm (18 lb-ft).
9. Position the radiator splash shield and install the 3 pin-type retainers.
10. Install the 2 generator-to-engine front cover studs. Tighten to 8 Nm (71 lb-in).
11. Install the 2 generator-to-engine front cover stud nuts. Tighten to 48 Nm (35 lb-ft).
12. Connect the camshaft position (CMP) sensor electrical connector.
13. Connect the crankshaft position (CKP) sensor electrical connector.
14. Position the power steering pump and fluid reservoir. Install the 3 power steering pump nuts. Tighten to 25 Nm (18 lb-ft).
15. Install the accessory drive belt tensioner and the bolt. Tighten to 45 Nm (33 lb-ft).
16. Install the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-233006-S24589360122006052400000) and «VALVE COVER - RH»(ref-233006-S03276844262006052400000) .
17. Install the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-233006-S05866754652006052400000) and «CRANKSHAFT FRONT SEAL»(ref-233006-S02414237342006052400000) .
18. Fill the engine with clean engine oil.
19. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-233006-S36803827612006052400000) .
2. Remove the ignition pulse wheel.
3. Install the damper bolt.
4. Remove the LH and RH spark plugs.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
10. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankcase key way in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the LH timing chain and timing chain guide.
14. Remove the damper bolt and the crankshaft sprocket.

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Install the crankshaft sprocket with the timing marks facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
7. Verify that the LH camshafts are correctly positioned.
8. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. Tighten to 25 Nm (18 lb-ft).
9. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
10. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
11. Verify that the RH camshafts are correctly positioned.
12. Install the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. Tighten to 25 Nm (18 lb-ft).
13. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
14. Remove the LH and RH timing chain tensioner piston retaining wires.
15. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
16. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
17. Remove the crankshaft damper bolt.
18. Install the ignition pulse wheel.
19. Install the LH and RH spark plugs. Tighten to 15 Nm (11 lb-ft).
20. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-233006-S36803827612006052400000) .

Scheme 31

Scheme 32

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

1. Remove the coolant pump. For additional information refer to «ENGINE COOLING»(ref-233003) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .
3. Remove the 3 bolts and the camshaft oil seal retainer.
4. Using a suitable press, remove the camshaft oil seal from the retainer. Discard the camshaft oil seal.
5. Loosen the LH camshaft bolts evenly in the sequence shown to allow the camshafts to rise from the cylinder head and remove the camshaft bearing and thrust caps.
6. Remove the camshafts from the LH cylinder head.

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
4. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
5. Install the camshaft oil seal retainer and the bolts. Tighten to 10 Nm (89 lb-in).
6. Position the new camshaft oil seal on the special tool.
7. Position the special tool and the camshaft oil seal on the camshaft.
8. Using the special tools, install the camshaft oil seal.
9. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .
10. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-233003) .

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .
2. Loosen the RH camshaft bolts evenly in the sequence shown to allow the camshafts to rise from the cylinder head and remove the camshaft bearing and thrust caps.
3. Remove the camshafts from the RH cylinder heads.

Scheme 39

Scheme 40

1. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
4. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-233006-S25884087122006052400000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

1. Using the special tool, install the valve seal.
2. Using the special tool, install the valve spring, retainer and key.
3. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-233006-S25884087122006052400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233006-S35976819572006052400000) .
3. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233003) .
4. Remove the LH camshafts. For additional information, refer to «CAMSHAFT - LH»(ref-233006-S17455189342006052400000) .
5. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-233006-S28246577182006052400000) .
6. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-233006-S00610074082006052400000) .
7. Remove the camshaft roller followers.
8. Remove the hydraulic lash adjusters.
9. Remove the bolts in the sequence shown.
10. Remove the cylinder head and support the cylinder head on a bench with the head gasket side up. Discard the gasket and the bolts.
11. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.0001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.0001 in).

Scheme 41

1. Use a plastic scraping tool to remove all traces of the head gasket. Clean all surfaces with silicone gasket remover and metal surface prep.
2. Position the new gasket and the cylinder head.
3. Install the 8 bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
6. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-233006-S00610074082006052400000) .
7. Install the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-233006-S28246577182006052400000) .
8. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233003) .
9. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233006-S35976819572006052400000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233006-S35976819572006052400000) .
3. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233003) .
4. Remove the RH camshafts. For additional information, refer to «CAMSHAFT - RH»(ref-233006-S31945825902006052400000) .
5. Remove the camshaft roller followers.
6. Remove the hydraulic lash adjusters.
7. Remove the 6 RH exhaust manifold nuts and position the manifold aside. Remove and discard the gasket.
8. Remove the bolt and detach the power steering pressure tube (PSP) bracket.
9. Remove the bolts in the sequence shown.
10. Remove the cylinder head and support the cylinder head on a bench with the head gasket side up. Discard the gasket and the bolts.
11. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.0001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.0001 in).

Scheme 42

Scheme 43

1. Use a plastic scraping tool to remove all traces of the head gasket. Clean all surfaces with silicone gasket remover and metal surface prep.
2. Position the new gasket and the cylinder head.
3. Install the 8 bolts and tighten in 6 stages in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen 1 full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
6. Position a new gasket, the RH exhaust manifold and install the 6 nuts. Tighten to 20 Nm (15 lb-ft).
7. Position the PSP tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
8. Install the RH camshafts. For additional information, refer to «VALVE COVER - RH»(ref-233006-S03276844262006052400000) .
9. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-233003) .
10. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-233006-S35976819572006052400000) .

Scheme 44

Scheme 45

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

Scheme 46

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the front catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-233005) .
3. Remove the 2 bolts and the front catalytic converter bracket.
4. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
5. Remove and discard the oil filter.
6. Remove the torque converter lower inspection cover.
7. Remove the 2 oil pan-to-transaxle bolts.
8. Remove the oil filter adapter-to-oil pan bolt.
9. Remove the 15 bolts and the oil pan. Remove and discard the gasket.

Scheme 47

1. Use a plastic scraping tool to remove all traces of the oil pan gasket. Clean all surfaces with metal surface cleaner.
2. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
3. Position the oil pan and a new gasket, and loosely install the bolts and stud bolts.
4. Install the oil pan-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
5. Tighten the oil pan-to-engine bolts in the sequence shown to 25 Nm (18 lb-ft).
6. Install the oil filter adapter-to-oil pan bolt. Tighten to 40 Nm (30 lb-ft) and then rotate 90 degrees.
7. Install a new oil filter. Tighten to 16 Nm (12 lb-ft).
8. Install the front catalytic converter bracket and the 2 bolts. Tighten to 40 Nm (30 lb-ft).
9. Install the front catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-233005) .
10. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the oil pan. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-233006-S19109809112006052400000) and «OIL PAN»(ref-233006-S11364195072006052400000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in). Remove and discard the O-ring seal.
4. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-233006-S19109809112006052400000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-233006-S03685841922006052400000) .
3. Remove the 8 nuts and the oil pan baffle. To install, tighten the oil pan baffle nuts in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten an additional 45 degrees.
4. To install, reverse the removal procedure.

Scheme 48

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .
3. Remove the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-233006-S19109809112006052400000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-233006-S03685841922006052400000) .
4. Remove the bolts in the sequence shown.
5. Remove the oil pump.

Scheme 49

1. Position the oil pump and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Install the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-233006-S19109809112006052400000) and «OIL PUMP SCREEN AND PICKUP TUBE»(ref-233006-S03685841922006052400000) .
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-233006-S06073398902006052400000) .

1. Remove the oil level indicator.
2. Remove the stud bolt and the oil level indicator tube. Remove and discard the O-ring seal. To install, tighten to 9 Nm (80 lb-in).
3. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-233003) .
3. Remove the lower radiator splash shield.
4. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233015) .
5. Disconnect the A/C compressor electrical connector and wiring harness retainer.
6. Remove the 2 bolts, 2 nuts and position the A/C compressor aside. To install, tighten to 25 Nm (18 lb-ft).
7. Remove the 6 bolts and position the A/C compressor bracket aside. To install, tighten to 25 Nm (18 lb-ft).
8. Disconnect the oil pressure sender electrical connector.
9. Remove the oil pressure sender. To install, tighten to 14 Nm (10 lb-ft).
10. To install, reverse the removal procedure. Apply pipe sealant with Teflon® to the oil pressure sender threads.

Scheme 50

1. Remove the cooling fans. For additional information, refer to «ENGINE COOLING»(ref-233003) .
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the 2 exhaust manifold-to-catalytic converter bolts. To install, tighten to 40 Nm (30 lb-ft).
4. Remove and discard the 6 exhaust manifold nuts. To install, tighten to 20 Nm (15 lb-ft).
5. Remove the exhaust manifold. Remove and discard the gasket.
6. Remove and discard the 6 exhaust manifold studs. To install, tighten to 12 Nm (9 lb-ft).
7. To install, reverse the removal procedure.

Scheme 51

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-233005) .
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the 3 bolts and the RH exhaust manifold heat shield To install, tighten to 11 Nm (8 lb-ft).
5. Disconnect the exhaust gas recirculation (EGR) system module tube from the exhaust manifold. To install, tighten to 40 Nm (30 lb-ft).
6. Remove and discard the 6 RH exhaust manifold nuts. To install, tighten to 20 Nm (15 lb-ft).
7. Remove and discard the 3 studs closest to the rear of the cylinder head. To install, tighten to 12 Nm (9 lb-ft).
8. Remove the RH exhaust manifold and gasket. Discard the exhaust manifold gasket.
9. Remove and discard the 3 remaining studs. To install, tighten to 12 Nm (9 lb-ft).
10. To install, reverse the removal procedure.

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
2. Remove the 4 throttle body bolts and position the throttle body aside. To install, tighten to 10 Nm (89 lb-in).
3. Remove the roll restrictor cross brace-to-roll restrictor bolt. To install, clean the bolt using a wire brush, apply new threadlock to the threads and tighten to 48 Nm (35 lb-ft).
4. Remove the 4 roll restrictor cross brace-to-strut tower bolts and the crossbar. To install, clean the bolts using a wire brush, apply new threadlock to the threads and tighten to 55 Nm (41 lb-ft).
5. Remove the 4 roll restrictor support bracket bolts and the support bracket. To install, clean the bolts using a wire brush, apply new threadlock to the threads and tighten to 55 Nm (41 lb-ft).
6. Detach the wiring retainer from the roll restrictor.
7. Remove the 2 bolts and the roll restrictor. To install, clean the bolt using a wire brush, apply new threadlock to the threads and tighten to 55 Nm (41 lb-ft).
8. To install, reverse the removal procedure.

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Scheme 125

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-233044) .
3. Disconnect the negative and positive battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
4. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233047) .
5. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
6. Remove the cowl vent screen. For additional information, refer to «WIPERS AND WASHERS»(ref-233042) .
7. Drain the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233008) .
8. Remove the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
9. Remove the exhaust flex pipe and LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-233005) .
10. Remove and discard the roll restrictor cross brace-to-roll restrictor bolt.
11. Remove and discard the 4 roll restrictor cross brace bolts and the cross brace.
12. Remove the bolt and detach the ground strap from the RH fender.
13. Disconnect the redundant clip, press the quick release coupling button and disconnect the fuel tube from the fuel rail.
14. Detach the fuel tube clip from the upper intake manifold.
15. Disconnect the vapor tube from the purge valve.
16. Disconnect the 2 powertrain control module (PCM) electrical connectors and detach the wiring conduit.
17. Disconnect the power steering reservoir hose and detach the retainer.
18. Remove the bolt and detach the ground wire from the LH fender.
19. Remove the nut and detach the B+ terminal from the battery cable.
20. Disconnect the shift cable.
21. Disconnect the 16-pin electrical connector and detach the wiring retainers. Detach the electrical connector from the shift cable bracket.
22. Remove the 2 bolts and position the shift cable aside.
23. Disconnect the shift cable.
24. Disconnect the 16-pin electrical connector and detach the wiring retainer. Disconnect the electrical connector from the shift cable bracket.
25. Remove the 3 shift cable bracket bolts and position the cable and bracket aside.
26. Disconnect the heater hose and the throttle body coolant hose.
27. Disconnect the brake booster vacuum hose from the upper intake manifold.
28. Disconnect the coolant hoses from the thermostat housing.
29. Detach the coolant tube retainers.
30. Disconnect the 10-pin electrical connector and detach the wiring retainers.
31. Disconnect the A/C high-pressure switch electrical connector.
32. Remove the bolt and disconnect the A/C compressor manifold tube assembly.
33. Remove the nut and position the A/C tubes aside.
34. Disconnect the transmission cooler hoses.
35. Disconnect the power steering cooler hose.
36. Remove the engine oil pan drain plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
37. If equipped, disconnect the block heater electrical connector and detach the wiring harness.
38. Remove the 2 pin-type retainers and the torque converter lower access plug.
39. Remove and discard the 4 torque converter nuts.
40. Remove the 3 engine-to-transaxle bolts and the LH catalytic converter bracket.
41. If equipped, remove the 2 driveshaft support bracket bolts.
42. If equipped, remove the bolts and disconnect the driveshaft. Position the driveshaft aside.
43. Using the special tool, lower the powertrain and subframe from the vehicle.
44. Remove the nuts and separate the stabilizer bar links from the struts.
45. Remove the nuts and separate the outer tie rods from the wheel knuckles. Discard the nuts.
46. Remove and discard the steering column intermediate shaft bolt. Detach the intermediate shaft from the steering gear.
47. Using the special tool, support the powertrain and the subframe.
48. Remove the 6 bolts and the 2 rear subframe brackets.
49. Remove the 2 forward subframe bolts and washers.
50. Remove the power steering pressure (PSP) tube bracket bolt and disconnect the PSP switch electrical connector.
51. Remove the bolt and disconnect the power steering fluid tubes.
52. Disconnect the RH catalyst monitor sensor electrical connector and detach the pin-type retainers from the subframe.
53. Disconnect the transaxle bulkhead electrical connector.
54. Detach the wiring harness retainer from the transaxle.
55. Detach the wiring harness retainers from the transaxle.
56. Detach the lower wiring harness retainers from the transaxle.
57. Remove the 4 bolts and the roll restrictor bracket.
58. Detach the wiring harness from the roll restrictor.
59. Remove the 2 bolts and the roll restrictor.
60. Remove the starter motor electrical connector cover.
61. Remove the nuts and disconnect the starter motor wiring.
62. Remove the 2 bolts and the starter motor.
63. Remove the bolt and disconnect the ground cable.
64. Disconnect the wire harness from the transmission control unit (TCU).
65. Remove the 4 bolts and the roll restrictor bracket.
66. Remove the 2 bolts and the roll restrictor.
67. Remove the starter motor electrical connector cover.
68. Remove the nuts and disconnect the starter motor wiring.
69. Remove the 2 bolts and the starter motor.
70. Remove the bolt and disconnect the ground cable.
71. Install the special tool to the RH cylinder head.
72. Install the special tool to the LH cylinder head.
73. Install the lower half of the special tool.
74. Install the upper half of the special tool.
75. Using the special tools and a suitable engine crane, support the powertrain.
76. Remove the front transaxle stabilizer bolt.
77. Remove the 3 bolts and the RH exhaust manifold heat shield.
78. Remove the RH engine insulator upper nut.
79. Remove the LH engine insulator upper nut.
80. If equipped, remove the upper power transfer unit (PTU) bracket bolts and the bracket.
81. Remove the 4 front transaxle insulator bracket bolts.
82. Remove the 3 front transaxle insulator bracket bolts.
83. Using the special tools and a suitable engine crane, lift the powertrain off of the subframe.
84. Lower the powertrain and support the transaxle using blocks of wood.
85. Position the knock sensor (KS) heat shield aside.
86. Disconnect the electrical connector and then remove the bolt and the KS.
87. Remove the engine-to-transaxle bolt.
88. Remove the 4 remaining transaxle-to-engine bolts. Separate the engine from the transaxle.
89. Remove the 4 remaining transaxle-to-engine bolts. Separate the engine from the transaxle.

Scheme 126

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1. Using the special tools and a suitable engine crane, align the engine with the transaxle.
2. Install the 4 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
3. Install the 3 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
4. Install the engine-to-transaxle bolt. Tighten to 40 Nm (30 lb-ft).
5. Position the knock sensor (KS), install the bolt and connect the electrical connector. Tighten to 20 Nm (15 lb-ft).
6. Attach the heat shield to the KS.
7. Using the special tools and a suitable engine crane, position the powertrain on the subframe.
8. Install the LH engine insulator upper nut. Tighten to 70 Nm (62 lb-ft).
9. Install the RH engine insulator upper nut. Tighten to 70 Nm (62 lb-ft).
10. Position the RH exhaust manifold heat shield and install the 3 bolts. Tighten to 11 Nm (8 lb-ft).
11. Install the front transaxle stabilizer bolt. Tighten to 40 Nm (30 lb-ft).
12. If equipped, install the upper power transfer unit (PTU) bracket and the bolts. Tighten to 55 Nm (41 lb-ft).
13. Clean the 3 rear transaxle insulator bracket bolts using a wire brush and apply new threadlock to the threads.
14. Install the 3 rear transaxle insulator bracket bolts. Tighten to 55 Nm (41 lb-ft).
15. Position the ground cable and install the bolt. Tighten to 12 Nm (9 lb-ft).
16. Position the starter motor and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
17. Position the starter motor wiring and install the nuts. Tighten the larger nut to 12 Nm (9 lb-ft). Tighten the smaller nut to 9 Nm (80 lb-in).
18. Install the starter motor terminal cover.
19. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
20. Position the roll restrictor and install the 2 bolts. Tighten to 55 Nm (41 lb-ft).
21. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
22. Position the roll restrictor bracket and install the 4 bolts. Tighten to 55 Nm (41 lb-ft).
23. Connect the transmission control unit (TCU) wire harness.
24. Clean the 4 rear transaxle insulator bolts using a wire brush and apply new threadlock to the threads.
25. Install the 4 rear transaxle insulator bracket bolts. Tighten to 55 Nm (41 lb-ft).
26. Position the ground cable and install the bolt. Tighten to 12 Nm (9 lb-ft).
27. Position the starter motor and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
28. Position the starter motor wiring and install the nuts. Tighten the larger nut to 12 Nm (9 lb-ft). Tighten the smaller nut to 9 Nm (80 lb-in).
29. Install the starter motor terminal cover.
30. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
31. Position the roll restrictor and install the 2 bolts. Tighten to 55 Nm (41 lb-ft).
32. Attach the wiring harness to the roll restrictor.
33. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
34. Position the roll restrictor bracket and install the 4 bolts. Tighten to 55 Nm (41 lb-ft).
35. Attach the lower wiring harness retainers to the transaxle.
36. Attach the wiring harness retainers to the transaxle.
37. Attach the wiring harness retainer to the transaxle.
38. Connect the transaxle bulkhead electrical connector.
39. Attach the pin-type retainers to the subframe and connect the RH catalyst monitor sensor electrical connector.
40. Connect the power steering fluid tubes and install the bolt. Tighten to 25 Nm (18 lb-ft).
41. Install the power steering pressure (PSP) tube bracket bolt and connect the PSP switch electrical connector. Tighten to 25 Nm (18 lb-ft).
42. Using the special tool, position the powertrain and subframe in the vehicle.
43. Install the 2 forward subframe bolts and washers. Tighten to 200 Nm (148 lb-ft).
44. Position the rear subframe brackets and install the 6 bolts. Tighten the 2 larger bolts to 150 Nm (111 lb-ft). Tighten the 4 smaller bolts to 55 Nm (41 lb-ft).
45. Attach the steering column intermediate shaft and install a new bolt. Tighten to 25 Nm (18 lb-ft).
46. Attach the outer tie rods to the wheel knuckles and install new nuts. Tighten to 115 Nm (85 lb-ft).
47. Attach the stabilizer bar links to the struts and install new nuts. Tighten to 55 Nm (41 lb-ft).
48. If equipped, connect the driveshaft and install the bolts. Tighten to 25 Nm (18 lb-ft).
49. If equipped, position the driveshaft support bracket and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
50. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
51. Position the oil pan and a new gasket. Loosely install the 15 bolts.
52. Position the LH catalytic converter bracket and install the 3 engine-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
53. Tighten the 15 oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
54. Install the oil filter adapter-to-oil pan bolt. Tighten to 40 Nm (30 lb-ft) and then tighten an additional 90 degrees.
55. Install the 4 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
56. Position the lower torque converter access plug and install the pin-type retainers.
57. If equipped, connect the block heater electrical connector and attach the wiring retainers.
58. Connect the power steering cooler hose.
59. Connect the transmission cooler hoses.
60. Position the A/C tube and install the nut. Tighten to 8 Nm (71 lb-in).
61. Position the A/C manifold assembly tubes and install the bolt. Tighten to 20 Nm (15 lb-ft).
62. Connect the A/C high-pressure switch electrical connector.
63. Connect the 10-pin electrical connector and attach the wiring retainers.
64. Position the coolant tube and secure the tube in the clips.
65. Connect the coolant hoses to the thermostat housing.
66. Connect the brake booster vacuum hose to the upper intake manifold.
67. Connect the heater hose and the throttle body coolant hose.
68. Position the shift cable bracket and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
69. Connect the 16-pin electrical connector and attach the wiring retainer. Connect the electrical connector to the shift cable bracket.
70. Connect the shift cable.
71. Position the shift cable bracket and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
72. Connect the 16-pin electrical connector and attach the wiring retainers. Attach the electrical connector to the shift cable bracket.
73. Connect the shift cable.
74. Attach the B+ terminal to the battery cable and install the nut. Tighten to 5 Nm (44 lb-in).
75. Position the ground wire on the LH fender and install the bolt. Tighten to 10 Nm (89 lb-in).
76. Connect the power steering reservoir hose and attach the retainer.
77. Connect the 2 powertrain control module (PCM) electrical connectors and attach the wiring conduit.
78. Connect the vapor tube to the purge valve.
79. Connect the fuel tube to the fuel rail. Connect the fuel tube redundant clip.
80. Attach the fuel tube retainer to the upper intake manifold.
81. Position the ground strap on the RH fender and install the bolt. Tighten to 10 Nm (89 lb-in).
82. Clean the 4 roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
83. Position the roll restrictor cross brace and install the 4 new bolts. Tighten to 55 Nm (41 lb-ft).
84. Clean the roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
85. Install a new roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
86. Install the LH and RH half shafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
87. Install the exhaust flex pipe and the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-233005) .
88. Install the cowl vent screen. For additional information, refer to «WIPERS AND WASHERS»(ref-233042) .
89. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
90. Fill the engine with clean engine oil.
91. Connect the negative and positive battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
92. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233047) .
93. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-233013) .
94. Fill and bleed the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-233008) .