Part 1

Engine

Special Tool(s):

Material:

Disassembly (Steps 1-27)

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.

1. Remove the 6 bolts and the flywheel.





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





3. Mount the engine on a suitable stand.
4. Remove the 4 bolts and the coolant pump pulley.





5. Remove the accessory drive belt idler pulley.





6. Disconnect the generator.
^ Remove the B+ wire terminal.
^ Disconnect the generator electrical connector.





7. Remove the 3 bolts and the generator.





8. Remove the bolt and the coolant pump extension tube and bracket.





9. Remove the 4 bolts and the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.





10. Remove the 4 bolts and the A/C compressor bracket.





11. NOTE: Remove and discard the coolant pump outlet tube O-ring.

Remove the coolant pump outlet tube.
^ Disconnect the 3 coolant hoses.
- Reposition the clamps.
^ Remove the 2 bolts and the coolant pump outlet tube.





12. Remove the 3 bolts and the accessory drive belt tensioner.





13. Remove the 4 bolts and the power steering pump bracket.





14. Disconnect the crankshaft position (CKP) sensor electrical connector.





15. Remove the catalyst monitor sensor electrical connector mounting bracket.





16. Remove the 4 bolts and the RH engine mount bracket.





17. Disconnect the oil pressure sensor electrical connector and remove the engine harness pin-type retainer.





18. Disconnect the camshaft position (CMP) sensor electrical connector.





19. Disconnect the intake manifold runner control (IMRC) electrical connector.





20. Disconnect the crankcase vent hose valve electrical connector and quick-connect the crankcase vent hose.





21. Disconnect the quick connect crankcase vent hose from the intake manifold and remove.





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





23. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Disconnect and remove the spark plug wires and retainers as an assembly.





24. Remove the 4 engine harness pin-type retainers.





25. Disconnect the knock sensor (KS) electrical connector.





26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.





27. Disconnect the:
1 Idle air control (IAC) electrical connector
2 Throttle position (TP) sensor electrical connector
3 Exhaust gas recirculation (EGR) system module electrical connector
4 EGR system module vacuum connector
5 EGR system module-to-exhaust manifold tube upper fitting