Part 1

ENGINE DISASSEMBLY - 2.5L

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 the pulley bolt is loosened. 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 exploded views, see - Engine Assembly.

Vehicles with manual transaxle





WARNING:The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow this instruction may result in serious personal injury.

CAUTION:Loosen the bolts evenly to prevent pressure plate damage.
1. Remove the bolts, clutch pressure plate and clutch disc.





2. Remove the bolts and the flywheel.

Vehicles with automatic transaxle





1. Remove the bolts and the flexplate.

All vehicles

1. Mount the engine on a suitable stand.





2. Disconnect the crankshaft position (CKP) sensor electrical connector.

- Detach the wiring harness-to-engine retainer.





3. Disconnect the generator electrical connection and the 2 wiring harness retainers.





4. Remove the nut and the generator wiring harness.





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





6. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.





7. Remove the 4 exhaust manifold heat shield bolts and the heat shield.





8. Remove and discard the 7 exhaust manifold nuts.

9. Remove the exhaust manifold and discard the exhaust manifold gasket.





10. Remove and discard the 7 exhaust manifold studs.

11. Clean and inspect the exhaust manifold. See Service and Repair.





12. Remove the 2 bolts and the accessory drive belt tensioner.





13. Loosen the bolt and remove the accessory drive belt idler pulley.





14. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.





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





16. Remove the bolts and the coolant pump.





17. Remove the 3 bolts and the thermostat housing assembly.





18. Remove the coolant tube retainer from the intake manifold.





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





20. Remove the 4 bolts and the oil filter adapter.

- Discard the gasket.





21. If equipped, remove the bolt and capacitor.





22. Disconnect the Variable Camshaft Timing (VCT) electrical connector.





23. Detach the wiring harness retainers from the RH side valve cover stud bolts.





24. Disconnect the crankcase vent hose from the valve cover.





25. Detach the wiring harness retainers from the LH side valve cover stud bolts.





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





27. Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.





28. Disconnect the EGR valve electrical connector.





29. Disconnect the Knock Sensor (KS) and detach the 2 wiring harness retainers.

30. Detach all the wiring harness retainers from the intake manifold.





31. Disconnect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.





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





33. Disconnect the radio capacitor electrical connector.





34. Disconnect the 4 fuel injector electrical connectors.

- Detach the 2 wiring harness retainers and remove the wiring harness assembly.





35. Remove the fuel rail insulator.





36. Remove the nut and the radio capacitor.





37. Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.





38. Remove the 8 bolts (3 shown) and position the intake manifold aside.