Part 1
DISASSEMBLY
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
CAUTION: 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tool, otherwise severe engine damage can occur.
CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
Vehicles with manual transaxle
1. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
Remove the bolts, clutch pressure plate and clutch disc.
2. Remove the starter motor isolator.
3. Remove the bolts and the flywheel.
Vehicles with automatic transaxle
4. Remove the bolts and the flexplate.
All vehicles
5. Mount the engine on a suitable stand.
6. Disconnect the crankshaft position (CKP) sensor electrical connector.
7. Remove the nut and disconnect the generator electrical connections.
8. Remove the 2 lower catalytic converter bolts.
9. Remove the 6 heat shield bolts and the heat shield.
10. Remove and discard the 7 exhaust manifold nuts.
11. Remove the catalytic converter and discard the exhaust manifold gasket.
12. Remove the bolts and the generator.
13. Loosen the bolt and remove the accessory drive belt idler pulley.
14. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
15. Remove the bolts and the coolant pump pulley.
16. Remove the bolts and the coolant pump.
17. Remove the engine vacuum tube.
^ Detach the 2 engine vacuum tube retainers.
^ Disconnect and remove the engine vacuum tube.
18. Detach the 2 wiring harness retainers and position the harness aside.
19. Disconnect the oil cooler hoses.
20. Remove the bolts and the thermostat housing assembly.
21. Remove the bolts and the oil level indicator.
22. Disconnect the oil pressure sensor electrical connector.
23. NOTE: Early build with oil cooler shown, late build without oil cooler similar.
Remove the oil filter, 4 bolts and the oil filter adapter.
^ Discard the oil filter and gasket.
24. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler.
^ Discard the oil cooler.
25. If equipped, remove the bolt and capacitor.
26. Detach the 2 wiring harness retainers.
27. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
28. Disconnect the temperature manifold absolute pressure (TMAP) electrical connector.
29. Disconnect the idle air control (IAC) motor electrical connector.
30. Disconnect the swirl control valve electrical connector.
31. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
32. Disconnect the throttle position (TP) sensor electrical connector.
33. NOTE: There are 3 different size bolts used. Mark the location of the bolts to ensure installation in the correct locations.
Remove the bolts and position the intake manifold aside.
34. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.