Part 1
DISASSEMBLY (Steps 1-38)
Engine
NOTICE: Do not loosen or remove the crankshaft pulley bolt 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 crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTICE: 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.
Vehicles equipped with a manual transaxle
1. 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.
NOTICE: Loosen the bolts evenly to prevent pressure plate damage.
Remove the 7 bolts, clutch pressure plate and clutch disc.
All vehicles
2. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Loosen the bolt and remove the accessory drivebelt idler pulley.
5. Remove the 3 bolts and the coolant pump pulley.
6. Remove the 3 bolts and the coolant pump.
7. Disconnect the heater hose and lower radiator hose from the thermostat housing.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
9. Remove the 4 bolts and the oil filter adapter.
^ Discard the gasket.
10. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
11. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
12. Disconnect the 4 fuel injector electrical connectors and detach the wiring harness retainers from valve cover stud bolts and intake manifold.
13. Remove the 2 bolts and the fuel rail with the fuel injectors.
14. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
16. If equipped, disconnect the swirl control valve solenoid electrical connector.
17. Disconnect the EGR valve electrical connector and if equipped, disconnect the swirl control valve sensor electrical connector.
18. Remove the bolt and the oil level indicator tube.
^ Discard the O-ring seal.
19. Remove the lower intake manifold bolt.
20. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
Loosen the 2 intake manifold bolts.
21. Remove the 5 intake manifold bolts.
22. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
^ Remove the intake manifold.
23. Remove the EGR tube.
24. Remove the radio interference capacitor bracket bolt and position the bracket aside.
25. Disconnect the EGR valve coolant hose.
26. Disconnect the coolant bypass hose.
27. Remove the 4 bolts and the coolant outlet.
28. Disconnect the coolant bypass hose.
29. Remove the 3 bolts, thermostat housing and thermostat.
30. Remove the 2 bolts, stud bolt and the A/C compressor.
31. Remove the bolt and the KS.
32. Remove the 8 bolts and the crankcase vent oil separator.
33. If equipped, remove the engine block heater.
34. Remove the 4 bolts and the ignition coil-on-plugs.
35. NOTICE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
Remove the spark plugs and the CHT sensor.
36. Remove the bolts and the valve cover.
37. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
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.
38. NOTICE: The Camshaft Alignment Plate 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 Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
