Disassembly
DISASSEMBLY
Engine
Special Tools And Equipment:
Special tool(s)
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur. Service and Repair
Vehicles with 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. Install the special tool and remove the flexplate.
3. Mount the engine on a suitable engine stand.
4. Remove the 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 front coolant outlet pipe.
1 Remove the bolts.
2 Remove the water outlet tube.
7. Remove the A/C compressor.
8. NOTE: The generator will be removed with the accessory bracket.
Remove the accessory bracket.
9. Remove the right motor mount.
10. Disconnect the following:
^ the coolant hose from the thermostat.
^ the coolant hose from the PCV fitting on the intake manifold.
11. Remove the coolant tube assembly.
12. Remove the exhaust manifold and gasket.
13. Remove the block heater, if so equipped.
14. Remove the rear coolant outlet pipe.
1 Disconnect the engine coolant temperature sender electrical connector.
2 Remove the coolant hose.
3 Remove the rear coolant outlet pipe and the mounting gasket.
15. Remove the EGR valve.
1 Disconnect the electrical connector.
2 Disconnect the coolant hose.
3 Remove the bolts and EGR valve.
16. Remove the power steering pump.
17. Disconnect the following electrical connectors:
^ Idle Air Control (IAC) valve
^ Throttle Position (TP) sensor
^ Manifold Absolute Pressure (MAP) sensor
18. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.
19. Disconnect the Knock Sensor (KS) electrical connector and remove the engine wiring harness connector bracket. Position the engine wiring harness aside.
20. Disconnect the Camshaft Position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.
21. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
22. Disconnect the EGR tube from the intake manifold.
23. Remove the EGR tube.
^ Remove the EGR tube bracket from the intake manifold.
^ Disconnect the EGR tube from the cylinder head.
^ Remove the EGR tube.
24. Detach the fuel supply hose clip from the front of the intake manifold.
25. Remove the intake manifold assembly.
26. Disconnect the fuel injector electrical connectors and the wiring harness pin-type retainers.
27. Disconnect the ignition coil and the Cylinder Head Temperature (CHT) sensor electrical connectors.
28. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
29. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
With a twisting motion, use the special tool to pull the spark plug wires off the spark plugs.
30. Remove the ignition coil.
31. Remove the thermostat housing.
32. Remove the KS and the engine vent cover.
33. Remove the left motor mount.
34. Remove the fuel injector supply manifold with the injectors and the ground strap.
35. Remove the water pump pulley.
36. Remove the water pump.
37. Remove the following:
^ CMP sensor
^ CHT sensor
^ spark plugs
38. Remove the valve cover.
39. Remove the CKP sensor.
40. CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, if the pulley is loosened, the crankshaft sprocket is also unfastened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No.1 piston at TDC.
41. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the special tool in the slots on the rear of both camshafts.
42. Install the special tools.
43. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolts can cause damage to the engine.
Remove the crankshaft pulley.
1 Remove the crankshaft pulley bolt.
2 Remove the special tools.
3 Remove the crankshaft pulley. Service and Repair
44. CAUTION: There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.
Remove the front cover.
45. 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.
46. Remove the timing chain guides.
47. Remove the timing chain assembly.
48. 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.
49. 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.
50. 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, sprockets and diamond washers.
51. Remove the special tool.
52. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Note 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.
53. Remove the camshafts.
54. Remove the bolts and the cylinder head.
55. Remove the cylinder head gasket.
56. Remove the cylinder head alignment dowels.
57. Remove the bolts and the oil pan.
58. Remove the rear main oil seal.
59. Remove the oil pump pickup tube and gasket.
60. Remove the oil pump assembly and gasket.