Disassembly

1. Ignition OFF. Disconnect the battery negative cable.

2. Remove the engine appearance cover.

3. Disconnect and remove the engine air cleaner cover and outlet pipe.

4. Position aside the accelerator cable and speed control cable (if equipped):

- Disconnect both the accelerator cable and speed control cable (if equipped) from the throttle body.

- Remove the accelerator cable and speed control cable bracket bolts and position the cables and bracket aside (if equipped).

5. Disconnect both the intake manifold left hand vacuum connections.

6. Disconnect the Idle Air Control (IAC) valve and Throttle Position Sensor (TPS) electrical connectors.

7. Disconnect the Exhaust Gas Recirculation (EGR) vacuum regulator electrical connector and vacuum connector.

8. Disconnect the crankcase ventilation hose, power brake booster vacuum hose, the EGR valve vacuum hose.

9. Loosen the fitting and disconnect the exhaust man ifold4o-EGR valve tube.

10. Disconnect the spark plug wires from the ignition coil, detach the routing clip pushpin, and position the wires aside.

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

11. Disconnect the radio interference capacitor electrical connector.

12. Disconnect the ignition coil electrical connector. Remove the ignition coil and bracket assembly.

13. Position aside the Powertrain Control Module (PCM) wire harness:

- Remove the retainer(s) attaching the wiring harness support bracket and ground wire to the bulkhead.

- Disconnect the PCM electrical connector and position the PCM wire harness aside.

14. Detach the knock sensor electrical connector from the intake manifold.

15. Remove the intake manifold refer to Workshop Manual (section 01-13C-1):

- Remove the intake manifold bolts and lift up the intake manifold.





- Remove the bolts retaining the heated PCV fitting, disconnect the fitting, and remove the intake manifold.

16. Disconnect the 42-pin engine electrical connector and detach from the left hand valve cover bracket.

17. Disconnect the Camshaft Position (CMP) Sensor, and Differential Pressure Feedback EGR (DPFE) transducer electrical connectors.

18. Disconnect the heated PCV valve hose, and remove the heated PCV valve.

19. Disconnect the fuel vapor hose, and vacuum harness from left hand valve cover.

20. Raise and support the vehicle (follow lifting and safety instructions found in the Workshop manual).

21. Remove the air deflector.

22. Drain the cooling system.

23. Disconnect the lower radiator hose from the radiator.

24. Lower the vehicle.

25. Disconnect the engine coolant temperature sensor electrical connector and the water temperature indicator sender unit connector.

26. Remove the upper radiator hose.

27. Disconnect the heater bypass hose from the thermostat housing.

28. Relieve the fuel system pressure using WDS Fuel Pressure Adapter Kit (418-F242). Place adapter on fuel rail schrader valve and place vent line into appropriate container. Slowly open the "T" valve to vent the fuel pressure. Remove the tool, refer to Workshop Manual (section 01-14-3):

29. Remove the fuel supply line.

- Remove the bolts from the fuel supply line and retaining clip on the left hand valve cover.





- Disconnect the fuel supply line from the fuel supply manifold and position aside.

30. Remove the left hand valve cover.

31. Disconnect all six (6) fuel injector connectors and position wiring aside.

32. Disconnect the fuel pulse damper vacuum hose.

33. Remove the fuel injection supply manifold.

34. Remove the right hand valve cover.

35. Disconnect the radiator overflow hose.

36. Loosen the fan clutch nut using Fan Pulley Holding Wrench 303-329 on 49UN01008 and Fan Clutch Nut Wrench 303-240 or 49-UN01-007.

37. Remove the fan shroud bolts.

38. Lift the fan shroud out of the lower retaining clips. Lift the fan shroud and the fan blade and clutch assembly together and remove from the vehicle.

39. Remove the lower radiator hose.

40. A/T vehicles: Disconnect the two (2) transmission cooler lines.

CAUTION:
Use 2-wrenches, one to hold the radiator fitting and one to remove the cooler line.

41. Disconnect the evaporative emissions port and remove the radiator.

NOTE:
To ease removal, tilt the radiator back and lift directly upward.

42. Rotate the camshaft until a cam lobe is in the up position and then remove its camshaft roller follower using Valve Spring Compressor 303-581.

CAUTION:
Mark each camshaft roller follower as it is removed to ensure its original position during assembly. Repeat this step for all roller cam followers.





43. Remove the accessory drive belt.

44. Remove the A/C line bracket bolt and position the A/C line aside.

45. Remove the accessory bracket bolts and position the bracket out of the way.

46. Remove the accessory drive belt tensioner.

47. Disconnect the generator and position the wiring aside.

48. Remove the generator mounting bracket.

49. Disconnect the Crankshaft Position (CKP) sensor electrical connector, detach the wiring anchors and position the wiring aside.

50. Remove the thermostat housing bolts, release the water pump bypass hose clamp, and remove the thermostat housing.

51. Disconnect the lower heater water hose from the water pump.

52. Remove and discard the crankshaft damper bolt.

CAUTION:
The crankshaft damper bolt is torque to yield and must be replaced.

53. Raise and support the vehicle.

54. Crankshaft damper removal:

- Vehicles equipped with a single mode crankshaft damper (grey):

a. Remove the crankshaft damper using Crankshaft Damper Remover 303-101 or 49UN010010.

b. Remove the crankshaft damper from the vehicle.

- Vehicles equipped with a dual mode crankshaft damper (black):

a. Install an extension bolt (M12x1.5X110 mm, obtained locally) into the crankshaft. Remove the crankshaft damper from the crankshaft using Universal Crankshaft Vibration Damper Remover 303-009 or 49UN-30-3009 or equivalent.

b. Remove the extension bolt and the crankshaft damper from the vehicle.

55. Remove the engine front cover lower bolts.

56. Lower the vehicle.

57. Remove the upper bolts and the engine front cover.

CAUTION:
Use care, coolant may spill into open oil pan and contaminate engine oil.