Part 1

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ENGINE DISASSEMBLY - 3.0L

Part 1 of 2

Disassembly

All vehicles

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 may cause engine failure.






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. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.






6. Disconnect the electronic throttle control electrical connector.






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






8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.






9. Detach the wiring harness retainer from the upper intake manifold.






10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.






11. Disconnect the RH coil-on-plug electrical connectors.

- Detach the 2 wiring harness retainers.

Front wheel drive (FWD) vehicles





1. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.

All vehicles





1. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.






2. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.






3. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.






4. Disconnect the fuel injector wiring harness electrical connector.






5. Disconnect the LH VCT electrical connector.






6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.






7. Disconnect the LH HO2S electrical connector.






8. Disconnect the 3 LH coil-on-plug electrical connectors.

- Detach the 2 wiring harness retainers.






9. Remove the nut and the B+ wire from the generator.






10. Detach the 2 wiring harness retainers.

- Remove the B+ harness from the engine.

Front wheel drive (FWD) vehicles





1. Remove the EGR tube fitting from the EGR valve.

All vehicles





1. Remove the 2 upper intake manifold bracket bolts (1 shown).






2. Remove the 7 bolts and the upper intake manifold.

- Remove and discard the gaskets.






3. Remove the 4 bolts and the fuel rail and injectors as an assembly.






4. Remove the 8 lower intake manifold bolts and the lower intake manifold.

- Remove and discard the gaskets.






5. Remove the 6 bolts and the 6 coil-on-plugs.

NOTE:When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
NOTE:LH shown, RH similar.

FWD vehicles





1. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.






2. Remove the 3 bolts and the RH heat shield.






3. Remove the 3 nuts and the RH catalytic converter.

- Discard the nuts and gasket.






4. Remove the 6 RH exhaust manifold nuts and the manifold.

- Discard the nuts and gasket.






5. Remove and discard the 6 RH exhaust manifold studs.

All vehicles





1. Remove the bolt, 2 nuts and the generator.






2. Remove the 3 bolts and the A/C compressor bracket.






3. Remove the 3 bolts and the LH heat shield.






4. Remove the stud bolt and the oil level indicator and tube.

- Remove and discard the O-ring seal.






5. Remove the 6 nuts, the LH catalytic converter and the gasket.

- Discard the gasket and nuts.






6. Remove and discard the 6 LH exhaust manifold studs.






7. Remove the EOP switch and, if equipped, the block heater.






8. Remove and discard the oil filter.






9. Position the Stretchy Belt Remover under the coolant pump belt as shown.






10. With the help of a assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.

NOTE:Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 152 mm (5.984 in).






11. 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 RH front of the vehicle removing the coolant pump belt.






12. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.

CAUTION: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.






13. Remove the 5 coolant pump housing bolts.






14. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.






15. Remove the nut and the radio interference capacitor.






16. Remove the bolts and the RH valve cover.

- Discard the gasket.






17. Remove the bolts and the LH valve cover.

- Discard the gasket.






18. Remove the 15 bolts and the oil pan.

- Discard the gasket.






19. Remove the 2 bolts and the oil pump screen and pickup tube.






20. Remove and discard the O-ring seal.






21. Remove the oil pan baffle.
a. Remove the 4 M6 oil pan baffle nuts.

b. Remove the 4 M8 oil pan baffle nuts.






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






23. Remove the crankshaft pulley bolt and washer.

- Discard the crankshaft pulley bolt.






24. Using the 3-Jaw Puller, remove the crankshaft pulley.






25. Using the Oil Seal Remover, remove and discard the crankshaft front seal.






26. Remove the 2 bolts and the LH VCT.

NOTE:Note the position of the alignment dowel on the engine front cover.






27. Remove the 2 bolts and the RH VCT.

NOTE:Note the position of the alignment dowel on the engine front cover.






28. Remove the 14 bolts, 2 stud bolts and the engine front cover.

- Discard the gaskets.

CAUTION:Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE:Note the location of all bolts and stud bolts for installation.






29. Remove the LH and RH spark plugs.

CAUTION:Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE:LH shown, RH similar.






30. Remove the ignition pulse wheel.

NOTE:This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).





Continued in Part 2 Part 2