Part 1

Special Tool(s):

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 may 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.





1. Remove the 6 bolts and the flywheel.

2. Mount the engine on a suitable engine 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. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.



11. Detach the vehicle high-voltage electrical system electrical connector retainer from the accessory drive belt tensioner.



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





13. Disconnect the electronic throttle control electrical connector.





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





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





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





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



18. Disconnect the A/C compressor electrical connector.



19. Remove the 3 bolts and the A/C compressor.



20. remove the 2 bolts and the A/C compressor bracket.





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



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



23. Disconnect the auxiliary coolant pump hose and the upper radiator hose.



24. Disconnect the EGR coolant hose and the auxiliary coolant pump hose.
^ Remove the upper radiator hose and the auxiliary coolant pump as an assembly.



25. Disconnect the vacuum hose from the intake manifold.





26. Remove the 2 bolts, the nut and the vacuum pump assembly.



27. Detach the 3 wire harness pin-type retainers from the intake manifold.

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





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

29. 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.





30. Remove the EGR tube.





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





32. Detach the 2 wiring harness retainers from the ignition coil stud bolts.
^ Remove the high voltage wiring harness.