Part 1
Engine
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.
All vehicles
1. Remove the bolts and the flexplate.
2. Remove the engine-to-transaxle separator plate.
3. Using the special tools, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Detach the engine control sensor wiring connectors from the upper intake manifold.
6. Detach the wiring retainer, remove the nut and the heated oxygen sensor (HO2S) electrical connector bracket.
7. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring harness retainers.
8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
9. Remove the 2 wiring harness retaining nuts.
10. disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
^ Detach the wiring harness retainer.
11. Remove the PCV tube.
12. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
13. Disconnect the throttle body coolant hose.
14. 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.
Remove the bolts and upper intake manifold.
^ Discard the gaskets.
15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
16. Disconnect the RH coil-on-plug electrical connectors and detach the wiring retainer.
17. Disconnect the radio interference capacitor electrical connector and detach the wiring retainers.
18. Disconnect the LH coil-on-plug electrical connectors and detach the wiring retainers.
19. Disconnect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and detach the wiring retainers.
20. Disconnect the generator electrical connector.
21. Remove the nut and the B+ wire from the generator.
22. Disconnect the 6 fuel injector electrical connectors.
23. Detach the 2 wiring harness retainers (1 shown).
^ Remove the fuel charging wiring harness from the engine.
24. Remove the nut and detach the 4 wiring harness retainers.
^ Remove the B+ harness from the engine.
25. 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.
Remove the bolts and the lower intake manifold.
^ Discard the gaskets.
26. CAUTION: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
NOTE: LH shown, RH similar.
Remove the bolts and the 6 coil-on-plugs.
Front wheel drive (FWD) vehicles
27. Disconnect the RH heated oxygen sensor (H02S) electrical connector.
28. Remove the 6 nuts, the RH exhaust manifold and the gasket.
^ Discard the gasket and nuts.
29. Remove and discard the 6 RH exhaust manifold studs.
30. Remove the bolts and the halfshaft support bracket.
All vehicles
31. Remove the bolt, 2 nuts and the generator.
32. Remove the 3 bolts and the A/C compressor bracket.
33. Remove the EOP switch and, if equipped, the block heater.
34. Remove the stud bolt and the oil level indicator and tube.
^ Remove and discard the O-ring seal
35. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal.
Using the special tool, remove the H02S.
36. Remove the nuts, the LH exhaust manifold and the gasket.
^ Discard the gasket and nuts.
37. Remove and discard the 6 LH exhaust manifold studs.
38. Remove and discard the oil filter.
39. Position the Stretchy Belt Remover under the coolant pump belt as shown.
40. NOTE: Feed the Stretchy Belt Remover onto the camshaft coolant pump pulley approximately 90 degrees.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
41. Remove the coolant pump belt.
^ Fold the Stretchy Belt Remover over the top of the coolant pump belt.
^ In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine, removing the coolant pump belt
42. NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
Using the special tools, remove the coolant pump pulley.
43. Disconnect the 2 hoses and remove the thermostat housing.
44. Remove the nut, stud bolt and the coolant bypass tube.