Steps 1-40

Engine





WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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: For additional information, refer to the exploded view under the Assembly procedure.

Vehicles with 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.

NOTE: Loosen the clutch pressure plate retaining bolts evenly, by two turns at a time.

Remove and discard the 6 clutch pressure plate retaining bolts, remove the clutch disc and pressure plate.





2. Remove the bolts and the flywheel.
- Discard the bolts.





Vehicles with automatic transaxle

3. Remove the bolts and the flexplate.
- Discard the bolts.





All vehicles

4. Mount the engine on a Engine Stand.





5. Disconnect the Evaporative Emission (EVAP) canister purge valve tube from the intake manifold.





6. Disconnect the brake booster vacuum tube from the intake manifold.





7. Detach the EVAP tube and coolant tube from the coolant outlet bracket retainer.





8. Remove the bolt for the EVAP canister purge valve and remove the brake booster vacuum tube and EVAP canister purge valve as an assembly.





9. Remove the 4 spark plug wires.





10. Disconnect the coolant hose from the coolant outlet.





11. Disconnect the coolant return hose from the cylinder head.
- Detach the coolant tube from the fuel rail retainers.





12. Remove the nut, bolt and the bracket from the coolant outlet.





13. Remove the 4 bolts and the coolant outlet and ignition coil assembly.
- Inspect and replace the gasket, if necessary.





14. Remove the 2 bolts and the engine lift eye.





15. Remove the screw and the oil level indicator and tube.
- Inspect and replace the O-ring seal, if necessary.





16. If equipped, remove the engine block heater.





17. Remove the 2 bolts and the fuel rail assembly.





18. Remove the 4 fuel injector clips and the 4 fuel injectors.





19. Remove and discard the 8 fuel injector O-ring seals.





20. Detach the Knock Sensor (KS) from the bottom of the intake manifold.





21. Remove the 7 bolts and the intake manifold.
- Disconnect the PCV hose from the intake manifold.





22. Remove the bolt and the oil cooler.





23. Remove the 4 bolts and the thermostat housing
- Inspect and replace the gasket, if necessary.





24. Remove the thermostat from the engine block.
- Inspect the thermostat seal and replace, if necessary.





25. NOTE: Mark the location of the 2 KS for installation.

Remove the 2 bolts and the 2 KS.





26. Remove the bolts and the crankcase vent oil separator.
- Inspect and replace the gasket, if necessary.





27. Remove the Engine Oil Pressure (EOP) switch.





28. Remove the bolt and the Crankshaft Position (CKP) sensor.





29. Remove the 2 bolts and the Variable Camshaft Timing (VCT) oil control solenoids.





30. Remove the nut and the Heated Oxygen Sensor (HO2S) electrical connector bracket.





31. Loosen the 12 retainers and remove the valve cover.
- Discard the gasket.





32. Remove the 1 engine mount stud.





33. Remove the 4 bolts and coolant pump pulley.





34. Remove the 9 bolts and the timing belt cover.





35. Remove the 3 bolts and the engine mount bracket.





36. NOTICE: Only rotate the crankshaft in a clockwise direction.

Using the crankshaft pulley bolt, turn the crankshaft clockwise until the markings on the camshaft phaser and sprockets are at the 11 o'clock position as shown.





37. Remove the engine plug bolt.





38. NOTE: The Crankshaft Top Dead Center (TDC) Timing Pin 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 the crankshaft pulley removal and installation.

Install the Crankshaft TDC Pin.





39. NOTE: Only rotate the crankshaft clockwise direction.

Rotate the crankshaft until it contacts the Crankshaft TDC Pin.





40. Using the Strap Wrench, remove the crankshaft pulley bolt and the crankshaft pulley.
- Discard the crankshaft pulley bolt.