Part 1

DISASSEMBLY

Engine

Special Tool(s):

Vehicles equipped with a manual transmission

1. CAUTION: Loosen the bolts evenly to prevent pressure plate damage.

NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel for assembly reference.

Remove the 6 bolts, the clutch pressure plate and the clutch disc.





2. Remove the 6 bolts and the flywheel.





Vehicles equipped with an automatic transmission
3. Remove the 6 bolts and the flexplate.





All vehicles
4. Remove the spacer plate.





5. Using the special tools, remove the crankshaft rear seal.





6. Mount the engine on a suitable stand.
7. Disconnect and detach the heated oxygen sensor (HO2S) electrical connector. Remove the nut and the ground wire.





8. Disconnect the heated positive crankcase ventilation (PCV) valve and the radio interference capacitor electrical connectors.





9. Remove the bolt and the accessory drive belt idler pulley.





10. Remove the 4 bolts and the generator mounting bracket, the generator, the accessory drive belt tensioner and the idler pulley as an assembly.





11. Disconnect the crankshaft position (CKP) sensor and the camshaft position (CMP) electrical connectors.
^ Detach the 2 wiring harness retainers.





12. If equipped, disconnect the A/C compressor clutch electrical connector and detach the wiring harness retainer.





13. Remove the 2 nuts, the 2 bolts and the A/C compressor and power steering pump bracket brace.





14. Remove the bolt and the A/C compressor and power steering pump bracket and, if equipped, the A/C compressor.





15. Disconnect the oil pressure sender electrical connector and detach the wiring harness retainer.





16. Disconnect and detach the HO2S electrical connector. Disconnect the knock sensor (KS) and the cylinder head temperature (CHT) sensor electrical connectors.
^ Remove the engine wiring harness.





17. Remove the 4 bolts and the coolant pump pulley.





18. Release the clamp and disconnect the bypass hose. Remove the bolt and the heater outlet tube.





19. Remove the 14 bolts and the lower intake manifold.
^ Remove and discard the 2 gaskets and 2 end seals.





20. Remove the 3 bolts, 2 stud bolts and the LH valve cover.
^ Remove and discard the gasket.





21. Remove the bolt and the oil level indicator and tube.





22. Remove the 6 nuts and the LH exhaust manifold.
^ Remove and discard the nuts and the gasket.





23. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 LH exhaust manifold studs.
24. Remove the bolts and the engine support insulator bracket. Remove the oil pressure sender.





25. Remove the 2 bolts, 3 stud bolts and the RH valve cover.
^ Remove and discard the gasket.





26. Remove the 6 nuts and the RH exhaust manifold.
^ Remove and discard the nuts and the gasket.





27. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 RH exhaust manifold studs.
28. Remove the bolts and the RH engine support insulator brackets.





29. CAUTION: If the rocker arms are to be reinstalled, they must be installed into their original positions. Mark the rocker arms for location.

Remove the 6 bolts, the 6 rocker arm pivots and the 6 rocker arms from both cylinder heads.





30. CAUTION: If the push rods are to be reinstalled, they must be installed into their original positions. Mark the push rods for location.

Remove the 6 push rods from both cylinder heads.





31. Remove the 8 cylinder head bolts from both cylinder heads.





32. Remove both cylinder heads.
^ Remove and discard both cylinder head gaskets.





33. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct positions.

Remove the 17 bolts and the oil pan.
^ Remove and discard the oil pan rear seal.





34. Remove the CMP sensor and the camshaft synchronizer.
1 Remove the 2 bolts and the CMP sensor.
2 Remove the bolt and washer assembly.
3 Remove the camshaft synchronizer.





35. Using the special tool to prevent the crankshaft rotation, remove the crankshaft pulley bolt and washer.





36. Using the special tools, remove the crankshaft pulley.





37. Using the special tool, remove the crankshaft front seal.
^ Discard the crankshaft front seal.





38. Remove the 4 nuts, 4 bolts, the stud bolt, the coolant pump and the gasket.
^ Discard the gasket.





39. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
1 Remove the 2 stud bolts.
2 Remove the bolt.

3 CAUTION: The cap screw is hidden. Make sure to remove it or the engine front cover will be damaged.

Remove the cap screw.
4 Slide the engine front cover and engine front cover gasket from the dowels.
^ Discard the gasket.

5 Remove the studs.





40. Remove the bolt and the camshaft synchronizer drive gear.





41. Compress the timing chain tensioner and install a retaining pin.





42. Remove the crankshaft gear, the camshaft gear and the timing chain as an assembly.





43. Remove the 2 bolts and the timing chain tensioner.





44. NOTE: If the valve tappets are to be reinstalled, they must be installed into their original locations. Mark the valve tappets for location.

Remove the 12 valve tappets.
1 Remove the 4 bolts.
2 Remove the valve tappet guide plate and retainer.
3 Remove the 12 valve tappets.