Part 1
EngineSpecial Service Tools
Disassembly
1. Remove the engine assembly.
2. Secure the engine to the engine stand.
^ Align the engine to the engine stand.
^ Adjust the engine stand legs into position.
^ Mount the engine to an engine stand.
^ Fully tighten the engine stand leg nuts.
3. Release the camshaft position (CMP) sensor connector block from the intake manifold assembly.
4. Remove the coolant manifold.
^ Remove the 4 bolts.
^ Disconnect the electrical connector.
5. Position the wiring harness support bracket aside for access.
^ Remove the 2 bolts.
NOTE: RH illustration shown, LH is similar.
6. Remove both the ignition coil-on-plug covers.
^ Release from the 2 clips.
NOTE: RH illustration shown, LH is similar.
7. Disconnect the 8 ignition coil-on-plug electrical connectors.
8. Remove the 8 ignition coil-on-plugs.
^ Remove the 8 bolts.
9. Disconnect the valve cover breather hose.
^ Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector.
^ Repeat the operation for the other side.
10. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
11. Disconnect the CMP sensor electrical connector.
^ Repeat the above procedure for the RH side.
12. Disconnect the cylinder head earth connector.
^ Remove the bolt.
^ Release the 3 clips.
13. Disconnect the knock sensors (KS) electrical connector.
14. Release the purge valve from the mounting bracket.
^ Disconnect the quick release connector.
^ Disconnect the electrical connector.
^ Remove the bolt.
15. Release the 5 air conditioning (A/C) harness retaining clips.
16. Remove the crankshaft position (CKP) sensor.
^ Disconnect the electrical connector.
^ Remove the Torx screw.
17. Remove the power steering pump mounting bracket.
^ Remove the 3 bolts.
^ Release the transmission cooler pipe clips.
18. Remove the A/C compressor mounting bracket.
^ Remove the 2 bolts.
19. Disconnect the starter motor connector.
20. Disconnect the oil temperature and oil pressure sensors.
21. Disconnect the generator connector.
22. Release the 4 clips securing the generator harness.
23. Remove the 10 intake manifold bolts.
CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
24. Remove the intake manifold.
^ Disconnect the brake booster vacuum hose from the intake manifold.
^ Discard the gaskets.
^ Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
25. Remove the accessory drive belt idler pulley.
^ Remove the bolt.
26. Remove the coolant pump pulley.
^ Remove the 3 bolts.
27. Remove the coolant pump.
28. Remove the generator.
^ Disconnect the electrical connector.
^ Remove the 3 bolts.
29. Remove the generator mounting bracket.
^ Remove the 4 bolts.
30. Remove the oil level indicator and tube.
^ Remove the nut.
^ Discard the O-ring seal.
31. Remove the RH valve cover.
^ Remove the 14 valve cover retaining bolts.
^ Remove and discard the valve cover gasket.
^ Remove and discard the valve cover plug aperture seals.
^ Repeat the operation for the LH side.
32. Remove the engine front cover.
^ Release the engine wiring harness clips.
^ Remove the 24 bolts.
^ Remove and discard the gasket.
33. Rotate the crankshaft until the flats on the camshafts are parallel with the cylinder head joint faces.
NOTE: The engine is now in the SAFE position.
34. Lock the crankshaft.
^ Install the special tool.
^ Install the screw.
35. Remove the RH VCT control unit.
^ Remove the 3 bolts.
^ Remove and discard the O-ring seals.
36. Install the special tool to the RH cylinder head.
^ Install the 3 bolts.
37. Remove the RH primary timing chain tensioner assembly.
^ Remove the 2 bolts.
38. Remove the RH primary timing chain tensioner guide.
^ Remove the bolt.
39. Remove the RH primary timing chain.
40. Remove the LH VCT control unit.
^ Remove the 2 bolts.
^ Remove the nut.
^ Remove and discard the O-ring seals.
41. Install the special tool to the LH cylinder head.
^ Install the 3 bolts.
42. Remove the LH primary timing chain tensioner.
^ Remove the 2 bolts.
43. Remove the LH upper and lower primary timing chain tensioner guides.
^ Remove the stud.
^ Remove the bolt.
44. Remove the LH primary timing chain.
CAUTION: Discard the bolts.
45. Remove the camshaft sprockets.
^ Remove the 2 bolts.
46. Remove the secondary timing chain tensioner and the secondary timing chain.
^ Remove the 2 bolts.
47. Remove the special tool from the LH cylinder head.
^ Remove the 3 bolts.
CAUTION: Evenly and progressively, release the camshaft bearing caps.
NOTE: Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).
48. Remove the camshaft bearing caps.
^ Remove the 20 bolts.
49. Remove the camshafts.
50. Install the special tool to the RH cylinder head.
^ Install the 3 bolts.
CAUTION: Discard the bolts.
NOTE: LH illustration shown, RH is similar.
51. Remove the camshaft sprockets.
^ Remove the 2 bolts.
NOTE: LH illustration shown, RH is similar.
52. Remove the secondary timing chain tensioner and the secondary timing chain.
^ Remove the 2 bolts.
CAUTION: Evenly and progressively, release the camshaft bearing caps.
NOTE: Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).
NOTE: LH illustration shown, RH is similar.
53. Remove the camshaft bearing caps.
^ Remove the 20 bolts.
CAUTION: The bolts can only be used twice, mark the bolts with a center punch. If two punch marks are visible, discard the bolts.
54. Remove the LH cylinder head assembly.
^ Remove the 12 cylinder head bolts.
^ With assistance remove the cylinder head.
^ Remove and discard the cylinder head gasket.
^ Clean the cylinder head locating dowels.
^ Clean the component mating faces.
^ Repeat the operation for the RH side.
55. Remove 4 bolts securing the engine mount bracket to the cylinder block.
CAUTION: Note the position of the bolt.
56. Remove the starter motor.
^ Remove the remaining starter motor bolt.
57. Remove the KS.
58. Remove the flexplate.
^ Remove and discard the 8 bolts.
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
59. Remove the oil pan.
^ Remove the 18 bolts.
^ Clean all the mating faces and reusable parts thoroughly and check for damage.
60. Remove the oil strainer pick-up assembly.
^ Remove the 2 bolts.
^ Remove and discard the O-ring seal.
61. Remove the baffle plate.
^ Remove the 6 bolts.
62. Remove the oil pump assembly.
^ Remove the 4 bolts.
^ Remove and discard the gasket.
^ Clean the component mating faces.
63. Remove the engine from the engine stand.
^ With assistance, remove the engine block from the stand.