Disassembly

Special Tools:

1. Remove the A/C idler pulley and bracket.
1. Remove the bolts.
2. Remove the A/C idler pulley and bracket.





2. Remove the generator drive belt lock bolt and lock





3. Remove the A/C mounting bracket.
1. Remove the generator pivot bolts.
2. Remove the generator.
3. Remove the A/C mounting bracket bolts.
4. Remove the A/C mounting bracket.





4. Remove the power steering pump bracket.
1. Remove the three bolts.
2. Remove the power steering pump bracket.
5. Disconnect the spark plug wires from the spark plugs.





6. Remove the distributor cap.





7. Remove the distributor assembly.
1. Remove the bolt.
2. Remove the distributor.





8. Remove the EGR tube.
1. Loosen nuts.
2. Remove the EGR tube.





9. Remove the PCV hose from the valve cover.
1. Remove the PCV hose from the separator.
2. Remove the PCV hose from the valve cover.





10. Disconnect hoses and electrical connectors.
1. Disconnect the EGR temperature sensor electrical connectors.
2. Disconnect the evaporator purge solenoid electrical connector.
3. Disconnect the EGR solenoid vacuum inlet hose.
4. Disconnect the EGR solenoid vacuum outlet hose.





11. Disconnect the connections.
1. Disconnect the coolant hose from the EGR housing.
2. Disconnect the vacuum lines from the bracket.





12. Disconnect the electrical connectors.
1. Disconnect the MAP/BARO solenoid electrical connector.
2. Disconnect the Throttle Position (TP) sensor and TP switch electrical connectors.
3. Disconnect the Idle Speed Control (ISC) electrical connector.





13. Disconnect the hoses.
1. Disconnect the coolant hose.
2. Disconnect the fuel pressure regulator vacuum hose.





14. Remove the PCV hoses.
1. Remove the engine wiring harness from the brackets and position aside.
2. Remove the PCV hose bracket screws.
3. Remove the PCV hose from the valve cover.





15. Remove the coolant bypass hose.
1. Release the clamps.
2. Remove the coolant bypass hose.





16. Remove the PCV hoses and tube.
1. Remove the bolt.
2. Release the clamp.
3. Remove the PCV hoses and tube.
4. Remove the upper intake manifold stabilizer bracket bolt.





17. Remove the EGR adapter plate bracket bolts.





18. Remove the upper intake manifold.
1. Remove the bolts.
2. Remove the upper intake manifold.





19. Disconnect the electrical connectors.
1. Disconnect the EGR solenoid electrical connector.
2. Disconnect the Knock Sensor (KS) electrical connector.





20. Disconnect the RH fuel injector electrical connectors.





21. Remove the engine wiring harness from the engine.
1. Disconnect the fuel injector electrical connectors.
2. Remove the lower intake manifold ground wire bolts and remove the engine wiring harness from the engine.





22. CAUTION: Make sure the fuel injection supply manifold insulators are removed with the fuel injection supply manifold.

Remove the fuel injection supply manifold and insulators.
1. Remove bolts.
2. Remove the fuel injection supply manifold and insulators.





23. Remove the upper timing belt cover bolt.





24. CAUTION: The lower intake manifold bolts and nuts must be removed using a two step method.

Remove the lower intake manifold bolts and nuts in the sequence shown.





25. Remove the lower intake manifold.





26. Remove the lower intake manifold gaskets.





27. Remove the coolant crossover tube assembly.
1. Remove the thermostat housing bolts.
2. Remove the coolant crossover tube bolts.
3. Remove the coolant crossover tube assembly.





28. Remove the knock sensor.
1. Disconnect the knock sensor electrical connector.
2. Remove the knock sensor bolt.
3. Remove the knock sensor.





29. Remove the water pump pulley.
1. Remove the bolts.
2. Remove the water pump pulley.





30. Remove the crankshaft bolt.





31. Using the special tool, remove the crankshaft pulley.





32. Remove the upper timing belt cover.
1. Remove the bolts.
2. Remove the upper timing belt cover.





33. Remove the lower timing belt cover.
1. Remove the bolts.
2. Remove the lower timing belt cover.





34. CAUTION: If the timing belt is to be reused, mark the direction of rotation on the tinting belt.

Remove the timing belt.
1. Remove the outer timing belt guide.
2. Remove the timing belt tensioner nut and the timing belt tensioner.
3. Remove the timing belt.





35. NOTE: LH shown, RH similar.

Using the special tool, remove the LH and RH camshaft sprockets.
1. Position the special tool.
2. Remove the camshaft sprocket bolt.
3. Remove the camshaft sprocket.





36. Remove the seal plate.
1. Remove the bolts.
2. Remove the seal plate.





37. Remove the oil level indicator tube assembly.
1. Remove the bolt.
2. Remove the oil level indicator tube assembly.





38. NOTE: Federal emission equipped shown, green states emission equipped similar.

Remove the LH exhaust manifold heat shield.
1. Remove the bolts.
2. Remove the LH exhaust manifold heat shield.





39. Remove the RH exhaust manifold heat shield.
1. Remove the bolts.
2. Remove the RH exhaust manifold heat shield.





40. NOTE: Federal emission equipped shown, green states emission equipped similar.

Remove the heat shield.
1. Remove the bolts.
2. Remove the heat shield.





41. Remove the LH exhaust manifold to RH exhaust manifold nuts.





42. Remove the LH exhaust manifold nuts in the sequence shown using a two step method.





43. Remove the exhaust manifold.
- Remove and discard exhaust manifold gasket.





44. Remove the RH exhaust manifold nuts in the sequence shown using a two step method.





45. Remove the RH exhaust manifold.
- Remove and discard the exhaust manifold gasket.





46. Remove the RH valve cover.
1. Remove the screws.
2. Remove the RH valve cover.





47. Remove the LH valve cover.
1. Remove the screws.
2. Remove the LH valve cover.





48. CAUTION: Loosening the rocker arm shaft bolts in one step may bend the rocker arm shaft.

Loosen the rocker arm shaft bolts using a two step method.





49. NOTE: Mark the location of the rocker arm shafts to ease installation.

Remove the rocker arm shaft and rocker arm assemblies from the rocker arm shaft supports.





50. NOTE: Use rubber bands to hold the valve tappet in the rocker arm shaft support during removal.

Remove the rocker arm shaft supports.





51. NOTE: The cylinder head bolts must be loosened in two steps or damage to the cylinder head may occur.

Loosen the cylinder head bolts in the sequence shown using a two step method.





52. Remove the cylinder heads from the cylinder block.
53. Discard the cylinder head gaskets.





54. NOTE: Mark the location of the water pump stud/bolt for ease of installation.

Remove the water pump bolts and the water pump.





55. Remove the crankshaft key.
1. Remove the crankshaft sprocket.
2. Remove the inner timing belt guide.
3. Remove the crankshaft key.





56. Remove the oil pan bolts in the sequence shown.





57. Remove the oil pan and discard the oil pan seals.





58. Remove the crankshaft rear oil seal retainer plate.
1. Remove the bolts.
2. Remove the crankshaft rear oil seal retainer plate. Discard the gasket.





59. Remove the oil pump bolts and the oil pump.
- Discard the oil pump gasket.

60. NOTE: If a carbon ridge can be felt or seen at the top of the bore, it must be removed before removing the piston assemblies.

Remove the carbon ridge from the top of the cylinder bore.





61. NOTE: All six connecting rod caps are removed the same way. Only one is shown.

Remove the connecting rod caps.
1. Remove the nuts.
2. Remove the connecting rod caps.

62. NOTE: Mark and record all six piston rods to make sure that they are installed into their correct cylinder bores during assembly.

NOTE: All six pistons and rod assemblies are removed the same way. Only one piston and rod assembly is shown.

NOTE: The connecting rod assemblies are numbered designating to which connecting rod each cap belongs. Keep all pistons and connecting rod assemblies with their respective connecting rod caps to ease installation.

Rotate the crankshaft until the piston to be removed is at Bottom Dead Center (BDC).





63. Install two pieces of rubber hose over the connecting rod bolts to prevent crankshaft journal contact.
64. Remove the piston and the upper half of the connecting rod bearing from its cylinder.





65. Loosen the eight crankshaft main bearing cap bolts in the sequence shown using a two step method.





66. Remove the crankshaft main bearing cap and the lower crankshaft main bearings.





67. CAUTION: The crankshaft is heavy. Be careful not to damage it when removing it from the cylinder block.

Carefully lift the crankshaft from the cylinder block.
68. Remove the upper crankshaft main bearings from the cylinder block.