Part 1

-
ENGINE - HYBRID DISASSEMBLY

Part 1 of 2

Disassembly

CAUTION:Do not loosen or remove the crankshaft pulley without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshafts and camshafts must be locked in place by special service tools, otherwise severe engine damage can occur.

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.
NOTE:Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE:For additional information, see the exploded views.

1. Remove the bolts and the flywheel.

2. Mount the engine on a suitable stand.

3. Release the locking tab and disconnect the Heated Oxygen Sensor (HO2S) electrical connector.

- Detach the connector from the engine wiring harness connector bracket.

4. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.

5. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

6. Remove the bolt and the engine wiring harness connector bracket.

7. Detach the 2 engine wiring harness pin-type retainers.

8. Remove the 7 nuts and the catalytic converter manifold.

- Discard the nuts and the exhaust manifold gasket.

9. Remove and discard the 7 exhaust manifold studs.

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

11. Disconnect the electronic throttle control electrical connector.

12. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.

13. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

14. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.

15. Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.

16. Detach the 4 wire harness pin-type retainers from the intake manifold.

17. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.

NOTE:The cylinder head side of the intake manifold is showing the location of the 7 bolts.

18. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.

- Remove the intake manifold.

19. Remove the EGR tube.

20. Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.

21. Detach the 2 wiring harness retainers from the fuel rail and the wiring harness retainer from the valve cover.

22. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach the wiring harness retainer from the valve cover stud bolt.

23. Detach the 2 wiring harness retainers from the ignition coil stud bolts.

- Remove the high voltage wiring harness.

24. Remove the fuel rail insulator.

25. Remove the nut and the radio capacitor.

26. Remove the 2 stud bolts and the fuel rail with the fuel injectors.

27. Disconnect the 4 coil-on-plug electrical connectors.

28. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.

29. Disconnect the EGR valve electrical connector and detach the wiring harness retainer from the valve cover stud bolt.

- Remove the engine control wiring harness from the engine.

30. Remove the 3 bolts and the coolant pump pulley.

31. Remove the 3 bolts and the coolant pump.

32. Disconnect the coolant hose.

33. Disconnect the EGR coolant hose and the heater hose.

- Remove the heater hoses, EGR coolant hose and the motor electronics coolant pump and hoses as a assembly.