Steps 1 - 50

DISASSEMBLY











Special Tool(s)

CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.





1. Remove the nuts and the A/C hose.
2. Rotate the drive belt tensioner counterclockwise and remove the drive belt.





3. Remove the bolts.





4. Remove the bolts and position the accessory bracket aside.





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





6. Disconnect the following:
- Camshaft Position (CMP) sensor electrical connector.
- Ignition coil electrical connector.
- Pin-type retainer.





7. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Remove the right side spark plug wires.





8. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Remove the left side spark plug wires.





9. Remove the bolts and the coil and bracket assembly.





10. Remove the hose.





11. Disconnect the upper radiator hose from the thermostat housing.





12. Remove the heater hose from the thermostat housing.





13. Release the hose clamp and remove the lower radiator hose.





14. Release the hose clamp and remove the lower heater water hose.





15. Disconnect the heater control valve vacuum hose.





16. Remove the bracket bolt and the heater water hose.





17. Remove the coolant tube.





18. Remove the Exhaust Gas Recirculation (EGR) tube.
19. Remove fuel supply tube retaining bolt from the right valve cover.





20. Remove the hose.





21. Disconnect the right side fuel injector electrical connectors.





22. Disconnect the left side fuel injector electrical connectors.





23. Disconnect the coolant temperature sensor electrical connector.





24. Remove the wiring anchors.





25. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





26. Remove the fuel charging wiring harness retainers.





27. Remove the fuel charging wiring harness.





28. Disconnect the fuel pulse damper vacuum hose and remove the vacuum harness.





29. Remove the fuel injection supply manifold.





30. Remove the LH valve cover.





31. Remove the RH valve cover.





32. Remove the fuel injectors.





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





34. Remove the oil level indicator tube.





35. Remove the knock sensor.





36. Remove the RH exhaust manifold and the gasket.





37. Remove the LH exhaust manifold and the gasket.





38. Remove the water pump.





39. Remove the bolt.





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





41. Remove the RH hydraulic chain tensioner.





42. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the special tool, remove the camshaft roller followers.





43. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Remove the RH camshaft sprocket bolt.





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





45. Remove the bolt.





46. Remove the LH hydraulic chain tensioner.





47. Remove the LH camshaft sprocket bolt.





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





49. Remove the bolt.





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