Disassembly
1. Remove engine and install on suitable stand.2. If manual transmission, loosen bolts one turn at a time and remove clutch pressure plate and clutch disc.
3. Remove bolts and flywheel or flexplate and reinforcement.
CAUTION: Special bolts are used for attaching flywheel to crankshaft. Keep flywheel-to-crankshaft bolts separate for installation.
4. Remove engine rear plate.
5. Drain oil from engine.
6. Remove oil filter.
7. Disconnect EGR transducer electrical connector.
8. Apply Penetrating Lubricant E8AZ-19A501-B or equivalent to EGR valve to exhaust manifold tube nuts. Loosen nuts and remove EGR valve to exhaust manifold tube.
9. Remove two nuts and rear engine lifting eye.
10. Remove exhaust manifold bolts and studs and exhaust manifold.
11. Remove right engine mount bracket.
12. Disconnect fuel pressure regulator vacuum line from fuel pressure regulator.
13. Remove vacuum connections from EGR valve (EGR valve).
14. Remove engine control sensor wiring and vacuum tab from top of valve cover.
15. Disconnect electrical connector at EGR vacuum realtor solenoid valve.
16. Remove two bolts and assembled EGR vacuum regulator solenoid and EGR vacuum regulator bracket.
17. Disconnect EGR valve vacuum connector.
18. Disconnect throttle position (TP) sensor connector and idle air control (IAC) valve connector.
19. Disconnect positive crankcase ventilation valve (PCV valve) and crankcase ventilation hose from crankcase vent oil separator.
20. Remove seven bolts, two studs and upper intake manifold with assembled throttle body. Remove intake manifold upper gasket.
21. Disconnect vacuum connection from vacuum fitting in upper intake manifold.
22. Remove crankcase ventilation hose from valve cover.
23. Remove left side spark plug wire set from coils and spark plugs, and snap clips off of valve cover.
24. Disconnect engine wiring harness clip from rear left side of valve cover.
25. Remove right side spark plug wire set from ignition coils and spark plugs.
26. Disconnect vacuum harness and engine wiring from right side of valve cover and remove vacuum harness.
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(Part 2 Of 2):
27. Remove two water inlet tube-to-generator bracket bolts and water pump inlet tube.
28. Disconnect engine control sensor wiring from ignition coils and radio voltage regulator capacitor.
29. Remove three bolts and generator mounting bracket from engine with ignition coils assembled.
30. Disconnect oil pressure sensor and engine coolant sensor electrical connections from the cylinder block.
31. Disconnect engine wiring from four fuel injector nozzles and two clips to fuel rail.
32. Remove clip on fuel charging wiring from stud on lower intake manifold.
33. Disconnect fuel charging wiring from crankshaft position sensor (CKP sensor).
34. Disconnect fuel charging wiring from camshaft position sensor (CMP sensor) and clip from stud on lower intake manifold.
35. Disconnect engine control sensor wiring from the 42 pin connector bracket mounted on the lower intake manifold.
36. Remove engine control sensor wiring.
37. Remove stud and engine oil level indicator tube.
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(Part 2 Of 2):
38. Remove bolt and audio ground cable from engine.
39. Remove lifting eye and lower intake manifold with assembled fuel injectors and fuel injection supply manifold.
40. Remove studs and bolts and remove lower intake manifold with assembled fuel injectors and fuel injection supply manifold
41. Remove left engine mount bracket.
42. Remove bolt and crankcase vent oil separator.
43. Remove engine coolant temperature sensor from cylinder block.
44. Using suitable oil pressure sender socket remove oil pressure sensor from cylinder head.
45. Remove eight spark plugs and use tape to label the reinstallation locations.
NOTE: Unique platinum spark plugs are used. If all eight spark plugs are not "PP" series, they will need to be marked for replacement in the same cylinder.
46. Remove crankshaft damper bolt and washer.
47. Remove crankshaft damper.
48. Remove outer timing belt cover bolt. Depress tabs and remove outer timing belt cover.
49. Remove bolt and crankshaft position sensor (CKP sensor).
50. Loosen timing belt tensioner spring pivot bolt one-half turn.
51. Hold timing belt tensioner with T74P-6254-A Camshaft Belt Tensioner Tool and remove adjusting bolt. Relax timing belt tensioner spring.
52. Remove timing belt.
53. Hold timing belt timing belt tensioner spring with T74P-6254-A Camshaft Belt Tensioner Tool and remove spring pivot bolt. Relax spring and remove spring and tensioner.
54. Install T74P-6256-B Cam Sprocket Holding/Removing Tool on camshaft sprocket.
55. Remove camshaft sprocket bolt and washer.
56. Install puller part of T74P-6256-B Cam Sprocket Holding/Removing Tool. Pull off camshaft sprocket.
57. Install T74P-6256-B Cam Sprocket Holding/Removing Tool on oil pump sprocket.
58. Remove oil pump shaft bolt and washer.
59. Install puller part of T74P-6256-B Cam Sprocket Holding/Removing Tool. Remove oil pump sprocket.
60. Remove crankshaft sprocket.
61. Remove inner timing belt cover.
62. Remove two screws, clutch pressure plate, water thermostat, and oil cooler return tube gasket.
63.
NOTE: Steps 1 through 63 take the engine down to a "long block." For further disassembly, continue. Remove three bolts, water pump, and O-ring.
64. Remove valve cover and valve cover gasket.
65. Remove cylinder head bolts.
66. Remove cylinder head, and head gasket.
NOTE: Steps 1 through 65 take the engine down to a "short block." For further disassembly, continue.
67. Remove four bolts from oil pump.
68. Remove oil pump and oil pump to cylinder block gasket.
69. Remove oil pan bolts and oil pan.
70. Remove oil pan gasket.
71. Using ridge reamer, remove ridge from top of cylinder bores. Put a rag in cylinder to keep shavings from between piston and bore. Follow instructions of tool manufacturer.
72. Rotate engine on stand so crankshaft is up.
73. Remove two bolts and nut and remove oil pump screen cover and tube as an assembly.
74. Using T74P-6700-B Front Cover Seal Remover, remove engine front cover seal.
75. Remove bolts and engine front cover.
76. Make sure connecting rod caps are marked so each cap can be kept with its rod.
77. Remove connecting rod nuts and four caps.
78. Remove main bearing bolts and main bearing caps.
NOTE: Each main bearing cap, except the rear cap, is marked with arrows pointing to the front of the engine. The number of arrows corresponds to the number of the main bearing cap. For example, one arrow for the front cap, two arrows for the number two cap.
79. Lift out crankshaft. Crankshaft rear oil sea will come out with crankshaft. Remove seal from crankshaft.
80. Remove upper main bearings from block. Store them so they can be put back in the same places if they are to be reused.
81. Remove lower crankshaft bearings from main bearing caps. Store them so they can be put back in the same caps if they are to be reused.
82. Replace connecting rod caps on connecting rods and install nuts finger-tight.
83. Remove piston and rod assemblies from engine. It may be necessary to tap the bottom of each piston with the end of a hammer handle to remove.
84. Use suitable Allen wrench to remove oil filter mounting insert, if necessary.
85. Remove front and rear oil gallery plugs, if necessary.
86. Disassemble piston and rod assemblies, if necessary.
87. Disassemble cylinder head, if necessary.
88. Clean and inspect parts. Repair or replace as necessary.
89. Clean old sealer from cylinder block and attaching parts.