Part 1

Engine

Disassembly (Steps 1-44)





Vehicles equipped with a manual transmission

1. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release.

NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.

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





All vehicles

2. Remove the flywheel or flexplate.





3. Remove the engine-to-transmission spacer plate.
4. Mount the engine to a suitable engine stand and remove the lifting equipment and Lifting Eyes.

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

Disconnect the spark plug wires from the ignition coil.





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

With a twisting motion, use the special tool to pull the spark plug wires off the spark plugs.





7. Detach the spark plug wire retainers from the LH valve cover stud bolts.





8. Detach the spark plug wire retainers from the RH valve cover stud bolts and remove the spark plug wires.





9. Disconnect the crankshaft position (CKP) sensor electrical connector. Detach the wiring harness retainer.





10. Detach the wiring harness retainer from the generator.





11. Disconnect the camshaft position (CMP) sensor, the oil pressure switch and, if necessary, the knock sensor (KS) electrical connectors. Detach the wiring harness and electrical connector retainers.





12. Disconnect the PCV valve and the differential pressure feedback EGR sensor electrical connectors. Detach the wiring harness retainer from the differential pressure feedback EGR sensor.





13. Disconnect the ignition coil, the engine coolant temperature (ECT) sensor and 6 fuel injector electrical connectors. Detach the 5 wiring harness retainers from the valve cover stud bolts. Remove the wiring harness.





14. Remove the bolt and the engine ground strap.





15. Remove the nuts and the LH engine lifting eye.





16. Remove the nuts and the RH engine lifting eye.





17. Remove the bolts and the ignition coil assembly.





18. Remove the bolts and the generator mounting bracket.





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





20. Remove the 4 bolts and the crankshaft pulley.





21. Remove the crankshaft damper bolt.





22. Using a the special tool, remove the crankshaft damper.





23. NOTE: To prevent stretching the valve cover gasket, loosen silicone gasket and sealant from the cylinder head by sliding a flat knife between the valve cover gasket and cylinder head.

Remove the valve covers.





24. Remove and discard the valve cover gaskets.





25. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the sealing surfaces.





26. Remove the rocker arms and the push rods.





27. Remove the 4 bolts, the fuel rail and the fuel injectors.





28. Remove the lower intake manifold.
^ Remove the 8 bolts.
^ Remove the lower intake manifold.





29. Remove and discard the intake manifold gaskets and end seals.





30. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the sealing surfaces.





31. Remove the screws and the CMP sensor.





32. Remove the camshaft synchronizer bolt.





33. NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.

Remove the camshaft synchronizer.





34. Remove the nut, the bolt and the starter splash shield.





35. Remove the 2 stud bolts, the bolt and the LH engine support insulator bracket.





36. Remove the bolts and the RH engine support insulator bracket.





37. Remove the exhaust manifold-to-EGR valve tube.





38. Remove the stud bolts, the bolts, both exhaust manifolds and the gaskets.
^ Discard the stud bolts, the bolts and the gaskets.





39. Remove the bolts and oil pan.





40. Remove the nuts and oil pan baffle.





41. Remove and discard the oil pan gasket.





42. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the surfaces.





43. Remove the bolts and the CKP sensor.





44. Remove the bolt and KS.