Part 1
DISASSEMBLY (Steps 1-38)
Engine
Special Tool(s):
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 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 service tools, otherwise severe engine damage can occur.
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: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE: Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early and late build engines.
Vehicles equipped with a manual transmission
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 7 bolts, clutch pressure plate and clutch disc.
All vehicles
2. Install the special tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
5. Remove the 3 nuts and the generator heat shield.
6. Remove the nut and disconnect the generator electrical connections and wiring harness retainer.
7. Remove the nut and the wiring harness retainer.
8. Remove the bolt, the 2 stud bolts and the generator.
9. Remove the 2 bolts and the accessory drive belt tensioner.
10. Loosen the bolt and remove the accessory drive belt idler pulley.
11. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
12. Remove the 3 bolts and the coolant pump pulley.
13. Remove the 3 bolts and the coolant pump.
14. Disconnect the heater hose from the thermostat housing.
15. Remove the 3 bolts and the thermostat housing.
16. Disconnect the oil pressure sensor electrical connector.
17. Remove the engine oil filter.
18. Remove the 4 bolts and the oil filter adapter.
^ Discard the gasket.
19. Disconnect the knock sensor (KS) electrical connector and pin-type retainer.
20. Remove the lower intake manifold bolt.
21. Disconnect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
22. Disconnect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
23. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
24. Detach the wiring harness pin-type retainer.
25. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
26. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
2.0L engines
27. If equipped, disconnect the secondary air injection (AIR) vacuum supply hose.
28. Disconnect the swirl control valve electrical connector.
29. Remove the bolt and the oil level indicator tube.
30. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
Remove the 7 intake manifold bolts.
2.3L engines
31. Disconnect the swirl valve electrical connectors and pin-type retainers.
32. Remove the 2 bolts and the oil level indicator and tube.
33. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
Remove the 7 intake manifold bolts.
All engines
CAUTION: 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.
34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
35. Remove the exhaust gas recirculation (EGR) tube.
36. Remove the radio interference capacitor bracket bolt and position the bracket aside.
37. Disconnect the wiring harness retainers from the valve cover studs and position aside.
38. Disconnect the fuel charging wiring harness.
^ Disconnect the fuel rail pressure and temperature sensor electrical connector.
^ Disconnect the 4 fuel injector electrical connectors.
^ Detach the wiring harness retainers.