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Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle

Galaxy 2000.75 (04.2000-02.2006)

Engine - 2.0L - Engine Galaxy 2000.75 (04/2000-02/2006)
Disassembly

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030A)

Locking Tool, Flywheel

303-254 (21-135)

Socket, Cylinder Head Bolt

303-392 (21-167)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-04 (21-031B)

Mounting Plate for 303-435

303-435-12 (21-150A)

Remover, Vibration Damper Hub

303-509 (21-213)
General Equipment
Oil filter strap wrench
Engine hoist
One bolt M6 x 60 mm
Two bolts M8 x 30 mm
Three bolts M8 x 25 mm
Materials
Name
Specification
High temperature grease
ESD-M1C220-A 

Disassembly
  1. Remove the intermediate shaft center bearing bracket.

  1. Using a suitable oil filter strap wrench, remove the oil filter.
    • Discard the filter.

  1. Disconnect the oil pressure switch electrical connector.

  1. Install the special tool.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.

  1. Install the special tool.
  1. Mount the engine on the mounting stand.
  1. Drain the engine.
    • Allow the oil to drain into a suitable container.
    • Discard the drain plug washer.

  1. NOTE:
    NOTE:Install a new oil drain plug washer.
    Install the oil drain plug.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Disconnect the engine cooling fan temperature switch and engine coolant temperature sender unit electrical connectors.

  1. Disconnect the ignition coil electrical connectors.

  1. Detach the generator wiring harness support guide from the cylinder head.

  1. Disconnect the throttle position (TP) sensor electrical connector.

  1. Disconnect the idle air control (IAC) valve electrical connector.

  1. Disconnect the power supply rail from the fuel injectors.

  1. Remove the engine rear lifting eye.

  1. Remove the ignition coil and spark plug wires.

  1. Remove the engine support plate bracket and the generator bracket from the cylinder head.

  1. Using the special tool, disconnect the coolant hose from the water pump.

  1. Remove the exhaust manifold heat shield.

  1. Remove the oil level indicator and tube.

  1. NOTE:
    NOTE:Pull back the accessory drive belt tensioner.
    Remove the power steering pump and generator bracket.

  1. Remove the exhaust manifold.
    • Discard the gaskets and retaining nuts.

  1. Remove the positive crankcase ventilation (PCV) tube.

  1. Remove the coolant outlet housing.
    • Discard the gasket.

  1. Detach the throttle body bracket from the throttle body.

  1. Remove the IAC valve.
    • Discard the gaskets.

  1. Remove the throttle body.
    • Discard the O-ring seal.

  1. Remove the intake manifold.
    • Discard the gaskets.

  1. Remove the engine support plate bracket and the engine front lifting eye.

  1. Remove the water pump pulley.

  1. Remove the engine support plate.
  1. Apply high temperature grease on the mating face of the special tool and the crankshaft pulley retaining bolt.

  1. Using three M8 x 25 mm bolts, attach the special tool to the crankshaft pulley.

  1. Using two M8 x 30 mm bolts, install the special tool to the crankshaft pulley.
  1. Remove the crankshaft pulley retaining bolt and remove the crankshaft pulley.
    • Discard the retaining bolt.

  1. Remove the valve cover.
    • Discard the gasket.

  1. Remove the engine upper front cover.
    • Discard the gasket.

  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    Turn the crankshaft to top dead center (TDC).

  1. Remove the timing chain upper guide.
    • Discard the guide.

  1. Using the special tool, remove the camshaft sprockets.

  1. CAUTION:
    CAUTION:Prevent the timing chain tensioner pivot bolt retaining washer from dropping into the timing case.
    Remove the timing chain tensioner arm.
    1. Remove the retaining washer.
    1. Using a M6 x 60 mm bolt, remove the timing chain tensioner pivot bolt.

  1. Remove the timing chain tensioner.
    • Discard the timing chain tensioner.

  1. Remove the engine front cover.
    • Discard the engine front cover.

  1. Remove the oil pump chain.
    1. Remove the chain tensioner.
    1. Remove the oil pump sprocket and chain.

  1. Remove the timing chain guide lower retaining bolt.

  1. Remove the timing chain guide upper retaining bolt.
  1. Remove the timing chain and the timing chain guide.

  1. Remove the camshafts.
    1. Remove the timing chain upper guide bracket.
    1. Remove the camshaft bearing caps.

  1. CAUTION:
    CAUTION:Do not remove the cylinder head bolts until the cylinder head has cooled to below 30°C.
    Remove the front three cylinder head bolts.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Discard the gasket.
  1. Remove the clutch disc and pressure plate. For additional information, refer to Section  308-01 Clutch.

  1. Using the special tool, lock the flywheel in position.

  1. Remove the flywheel.
    • Discard the bolts.

  1. Remove the water pump.
    • Discard the O-ring seal.

  1. Remove the oil pump.
    • Discard the gasket.

  1. Remove the oil pressure switch.

  1. Remove the crankshaft position (CKP) sensor.

  1. Remove the oil pan.
    • Discard the gasket.

  1. Remove the oil baffle.

  1. Remove the oil pump pick-up tube.
    • Discard the gasket.

  1. Remove the front arch.

  1. Remove the crankshaft rear oil seal carrier.
    • Discard the gasket.
  1. Using a suitable press remove the oil seal on a flat surface.
    • Discard the oil seal.

  1. NOTE:
    NOTE:Keep the connecting rod bearing caps and bearing shells in order for installation.
    Remove the connecting rod bearing caps.
  1. Remove the pistons.

  1. NOTE:
    NOTE:Keep the crankshaft bearing caps, bearing shells and thrust half-washers in order for installation.
    Remove the crankshaft main bearing caps.
  1. Remove the crankshaft.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle