Part 1

Disassembly Note

Warning:
^ If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.

1. Rotate the drive belt tensioner counterclockwise and remove the drive belt.
2. Remove the bolts and position the accessory bracket aside.





3. Remove the generator mounting bracket.
1) Remove the drive belt tensioner bolt.
2) Remove the generator mounting bracket bolts.





4. Disconnect the throttle position (TP) sensor electrical connector.





5. Disconnect the idle air control (IAC) valve electrical connector and disconnect the EGR valve vacuum hose.





6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.





7. Disconnect the ignition coil electrical connector.





8. Disconnect the radio ignition interference capacitor electrical connector.





9. Disconnect the EGR vacuum regulator.





Caution:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.

10. Using spark plug wire remover SST 303-106, remove the spark plug wires from the spark plugs and all routing clips.





11. Remove the bolts.





12. Remove the bolt and the coil and the ignition wires.





13. Disconnect the vacuum hoses.





14. Detach and disconnect the electrical connector.





15. Remove the intake manifold bolts and lift up the intake manifold.





16. Remove the heated PCV hose retainers and remove the heated PCV fitting.





17. Remove the intake manifold.
18. Remove the bolts.





19. Detach the wiring harness retainer and remove the heater tube and bracket assembly.





20. Disconnect the camshaft position (CMP) sensor electrical connector.





21. Disconnect the differential pressure feedback EGR transducer





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





23. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ETC) sensor electrical connectors.





Note:
^ The LH side is shown, the RH side is similar.

24. Disconnect the six fuel injector electrical connectors.





25. Remove the engine control/fuel charging wiring.





26. Disconnect the EGR valve-to-exhaust manifold tube from the exhaust manifold.





27. Remove the bolt and position the lower fuel line bracket aside.





28. Remove the fuel rail.





29. Remove the LH valve cover and the gasket.





30. Remove the RH valve cover and the gasket.





31. Remove the fuel injectors.





32. Remove the thermostat housing.
1) Remove the bolts.
2) Release the bypass hose clamp.





33. Remove the oil level indicator tube.





34. Remove the knock sensor.





35. Remove the RH exhaust manifold and the gasket.





36. Remove the LH exhaust manifold and the gasket.





37. Remove the water pump.





38. Remove the bolt.





39. Using Crankshaft Damper Remover SST 303-101 (or 49UN-01-0010), remove the crankshaft pulley.





40. Remove the RH hydraulic chain tensioner.





Note:
^ Mark each camshaft roller follower to make sure of its original position during reassembly.

41. Using Valve Spring Compressor SST 303-581, remove the camshaft roller followers.





Caution:
^ The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

42. Remove the RH camshaft sprocket bolt.





43. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





44. Remove the bolt.





45. Remove the LH hydraulic chain tensioner.





46. Remove the LH camshaft sprocket bolt.





47. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





48. Remove the bolt.





49. Remove the bolts in the sequence shown and remove the LH cylinder head.