Disassembly
Engine
Special Tool(s)
Vehicles equipped with a manual transmission
1. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch release.
NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
Remove the bolts, the clutch pressure plate and the clutch disc.
All vehicles
2. Remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Remove the accessory drive belt.
5. Remove the engine oil level indicator assembly.
1 Remove the engine oil level indicator.
2 Remove the bolts.
3 Remove the engine oil level indicator tube.
6. Remove the coolant bypass.
1 Remove the hose.
2 Remove the bolts and the coolant bypass.
7. Remove the generator.
8. Disconnect the coolant tube from the exhaust gas recirculation (EGR) valve.
9. Disconnect the heater hose from the thermostat housing.
10. Disconnect the knock sensor (KS) electrical connector.
11. Remove the block heater, if equipped.
12. Remove the EGR valve.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the EGR valve.
13. Disconnect the throttle position (TP) sensor electrical connector.
14. Disconnect the idle air control (IAC) motor electrical connector.
15. Disconnect the swirl control valve monitor electrical connector.
16. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
17. Disconnect the camshaft position (CMP) sensor electrical connector.
18. Remove the positive crankcase ventilation (PCV) hose.
19. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
20. Remove the intake manifold assembly.
21. Disconnect the fuel injector electrical connectors and the wiring harness pin-type retainers.
22. Position aside the cylinder head temperature (CHT) boot.
23. Disconnect the CHT sensor electrical connector.
24. Remove the bypass hose.
25. Remove the thermostat housing.
26. Remove the knock sensor and the engine vent cover.
27. Remove the fuel injection supply manifold with the injectors.
28. Remove the coolant pump pulley.
29. Remove the coolant pump.
30. Remove the bolts and the ignition coils.
31. Remove the following:
^ CMP sensor.
^ CHT sensor.
^ Spark plugs.
32. Remove the valve cover.
33. Remove the CKP sensor.
34. Remove the crankshaft vibration damper bolt and the vibration damper.
35. Remove the engine front cover.
36. Remove the timing chain tensioner.
1 Compress the timing chain tensioner plunger and insert a paper clip into the location shown.
2 Remove the bolts.
37. Remove the timing chain guides.
38. Remove the timing chain assembly.
39. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
Remove the camshaft drive sprockets.
40. Remove the oil pump chain tensioner and guide.
1 Release the tension on the tensioner spring.
2 Remove the tensioner and the shoulder bolt.
3 Remove the guide.
41. NOTE: The oil pump chain sprocket must be held in place.
Remove the oil pump chain and sprockets.
1 Remove the bolt.
2 Remove the chain and sprockets.
42. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Mark the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
Remove the camshaft bearing caps.
1 Loosen the camshaft bearing cap bolts in sequence, one turn at a time.
2 Repeat the first step until all tension is released from the camshaft bearing caps.
3 Remove the camshaft bearing caps.
43. Remove the camshafts.
44. Remove the bolts and the cylinder head.
45. Remove the cylinder head gasket.
46. Remove the cylinder head alignment dowels.
47. Remove the bolts and the oil pan.
48. Remove the crankshaft rear main oil seal.
49. Remove the oil pump pickup tube and gasket.
50. Remove the oil pump assembly and gasket.