Part 2
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ENGINE DISASSEMBLY - 2.3L
Part 2
Continued From Part 1 Part 1
1.
CAUTION:Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
CAUTION:It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
With a twisting motion, use the spark plug wire remover SST to pull the spark plug wires off the spark plugs.
1. Remove the ignition coil.
1. Remove the thermostat housing.
1. Remove the bolt, the KS and the engine vent cover.
1. Remove the left motor mount.
1. Remove the fuel injector supply manifold with the injectors and the ground strap.
1. Remove the water pump pulley.
1. Remove the water pump.
1. Remove the CMP sensor, CHT sensor and the spark plugs.
1. Remove the valve cover.
NOTE:The CKP sensor cannot be reused. A new CKP sensor must be installed.
1. Remove the CKP sensor.
1.
CAUTION: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, with diamond washers between the flange faces on each part. For that reason, if the pulley is loosened, the crankshaft sprocket is also unfastened. If you loosen the pulley bolt before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, Otherwise severe engine damage may occur.
CAUTION:Failure to position the No. 1 piston at top dead center (TDC) may result in damage to the engine. Turn the engine in the normal direction of rotation only.
CAUTION:Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No.1 piston at top dead center (TDC).
1.
CAUTION:The camshaft alignment plate SST 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 alignment plate SST cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the alignment plate SST in the slots on the rear of both camshafts.
1. Install the holding fixture SST and the crankshaft pulley/holding tool SST.
1.
CAUTION:The crankshaft must remain in the top dead center (TDC) position during removal of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
CAUTION:If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft. Failure to follow this instruction may cause engine damage.
Remove the crankshaft pulley.
a. Remove the crankshaft pulley bolt.
b. Remove the holding fixture SST and the crankshaft pulley/holding tool SST.
c. Remove the crankshaft pulley.
1.
CAUTION:There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.Remove the front cover.
1. Remove the timing chain tensioner.
a. Compress the timing chain tensioner plunger and insert a paper clip into the location shown.
b. Remove the bolts.
1. Remove the timing chain guides.
1. Remove the timing chain assembly.
1.
NOTE:Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.Remove the camshaft drive sprockets.
1. Remove the oil pump chain tensioner and guide.
a. Release the tension on the tensioner spring.
b. Remove the tensioner and the shoulder bolt.
c. Remove the guide.
1.
NOTE:The oil pump chain sprocket must be held in place.Remove the oil pump chain and sprockets.
a. Remove the bolt.
b. Remove the chain, sprockets and diamond washers.
1. Remove the camshaft alignment plate SST.
1.
CAUTION:Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE:Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
Remove the camshaft bearing caps.
- Loosen the camshaft bearing cap bolts in sequence, one turn at a time.
- Repeat the first step until all tension is released from the camshaft bearing caps.
- Remove the camshaft bearing caps.
2. Remove the camshafts.
1. Remove the bolts and the cylinder head.
2. Remove the cylinder head gasket.
1. Remove the cylinder head alignment dowels.
1. Remove the bolts and the oil pan.
1. Remove the rear main oil seal.
1. Remove the oil pump pickup tube and gasket.
1. Remove the oil pump assembly and gasket.