Special Tools

1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

Warning: Refer to Battery Disconnect Warning in the Preface section.

3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
5. Drain the engine oil.
6. Drain the transaxle oil.



7. Drain the power steering oil.
8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
9. Remove the engine assembly using the J 39580  (1). Refer to Engine Replacement.



10. Remove the flexible plate bolts and the flexible plate.
11. Support the engine assembly with the OTC 1726 .



12. Remove the intake manifold. Refer to Intake Manifold Replacement.



13. Remove the cylinder head cover. Refer to Cylinder Head Cover Replacement.



14. Remove the drive belt.



15. Remove the oil pan. Refer to Oil Pan Replacement.




Note: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.

16. Install the EN-47610  (1) to the crankshaft pulley bolt.



17. Remove the crankshaft pulley bolt using the EN-47611  (2).



18. Remove the engine mount bracket support.



19. Remove the water pump pulley.



20. Remove the drive belt automatic tensioner retaining bolts and the tensioner.



21. Remove the timing chain cover.
22. Remove 2 dowel rings for timing cover.



23. Remove the timing chain tensioner.



24. Remove the fixed timing chain guide.



25. Remove the timing chain lever.



26. Remove the top chain guide.
27. Remove the timing chain.
28. Remove the crankshaft sprocket and the woodruff key.

1. Install the crankshaft sprocket and the woodruff key.
2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using the EN-47613  (1).



3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
4. Adjust the crankshaft using the EN-47617  (1).



5. Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, ant crankshaft sprocket respectively.

Caution: Refer to Fastener Caution in the Preface section.




6. Install the fixed timing chain guide.

Tighten
Tighten the fixed timing chain guide bolts to 20 N·m (15 lb ft).




7. Install the timing chain lever.

Tighten
Tighten the timing chain lever bolt to 20 N·m (15 lb ft).




8. Install the timing chain tensioner.

Tighten
Tighten the timing chain tensioner bolt to 20 N·m (15 lb ft).




9. Install the top chain guide.

Tighten
Tighten the top chain guide bolt to 10 N·m (89 lb in).




10. Install 2 dowel rings.
11. Apply the liquid gasket Loctite® 5900-M8585 on the timing chain cover.




Note: Be sure the applied liquid gasket is not damaged when installing the timing chain cover.

12. Install the EN-47612  (1) and position the timing chain cover.



13. Install the timing chain cover.

•	Tighten the timing chain cover center bolt to 20 N·m (15 lb ft).

•	Tighten the timing chain cover bolts to 8 N·m (71 lb in).




14. Install the drive belt automatic tensioner and tighten the retaining bolt to 25 N·m (18 lb ft).



15. Install the water pump pulley and tighten the bolts to 10 N·m (89 lb in).



16. Install the engine mount bracket support and tighten the bolts to 28 N·m (21 lb ft).



17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the EN-47610  (1) and the EN-47611  (2). Tighten the crankshaft pulley bolt to 550 N·m (406 lb ft)



18. Install the oil pan. Refer to Oil Pan Replacement.



19. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement.
20. Install the drive belt.



21. Install the intake manifold. Refer to Intake Manifold Replacement.



22. Install the flexible plate and tighten the bolts to 75 N·m (55 lb ft).



23. Mount the engine on the J 39580  (1).
24. Install the transaxle to the engine assembly.
25. Install the engine and transaxle assembly. Refer to Engine Replacement.
26. Install the fuel pump fuse.
27. Connect the negative battery cable.
28. Refill the crankcase with engine oil.
29. Refill the engine coolant system. Refer to Cooling System Draining and Filling.
30. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.
31. Refill the A/C system. Refer to Refrigerant Recovery and Recharging.