Part 2
ENGINE - 2.3L DISASSEMBLY Continued39. Detach the wiring harness retainer.
40. Disconnect the EGR valve electrical connectors.
^ Detach the wiring harness retainer.
41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
42. Detach the wiring harness retainer.
43. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.
^ Remove the wiring harness from the engine.
44. Disconnect the coolant hose.
45. Disconnect and remove the coolant hose.
46. Disconnect and remove the coolant hoses.
47. Remove the bolt and the KS.
48. Remove the bolts and the crankcase vent oil separator.
49. If equipped, remove the block heater.
50. Remove the crankcase vent tube and the coil-on-plugs.
51. Remove the spark plugs and the CHT sensor.
^ Discard the CHT.
Caution
^ Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
52. Remove the bolts and the valve cover.
53. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
^ The hole in the crankshaft pulley should be in the 6 o'clock position.
Caution
^ Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
54. Install the special tool in the slots on the rear of both camshafts.
Caution
^ The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Note
^ The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
55. Remove the engine plug bolt.
56. Install the special tool.
Note
^ The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly.
57. Assemble the special tools using 4 hardened washers in the locations shown.
58. Using special tools and an air impact wrench, remove the crankshaft pulley.
^ Remove and discard the crankshaft pulley bolt and washer.
^ Remove the crankshaft pulley.
Caution
^ The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
Caution
^ If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft. If the washer is not installed, engine damage may occur.
59. Using the special tool, remove the crankshaft front oil seal.
Caution
^ Use care not to damage the engine front cover or the crankshaft when removing the seal.
60. Remove and discard the CKP sensor.
Note
^ Whenever the CKP sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
61. Remove the bolts and the engine front cover.
62. Remove the timing chain tensioner.
(1) Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
(2) Remove the bolts and timing chain tensioner.
63. Remove the RH timing chain guide.
64. Remove the timing chain.
65. Remove the bolts and the LH timing chain guide.
66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
Caution
^ Do not rely on the camshaft alignment plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
67. Remove the oil pump chain tensioner and guide.
(1) Release the tension on the tensioner spring.
(2) Remove the tensioner and the shoulder bolt.
68. Remove the oil pump chain and sprockets.
(1) Remove the bolt.
(2) Remove the chain and sprockets.
Note
^ Remove the crankshaft sprocket diamond washers located in front of and behind the crankshaft sprocket.
Note
^ The oil pump chain sprocket must be held in place.
69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
70. Remove the camshafts from the engine.
^ Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
^ Remove the camshaft bearing caps.
^ Remove the camshafts.
Caution
^ Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
71. Remove the cylinder head.
^ Remove and discard the cylinder head bolts.
^ Remove the cylinder head.
^ Remove and discard the cylinder head gasket.
72. Remove the cylinder head alignment dowels.
73. Remove the bolts and the oil pan.
74. Remove the bolts and the rear crankshaft seal.
75. Remove the bolts, oil pump pickup tube and gasket.
76. Remove the bolts and the oil pump.
