Part 1 of 2

Engine








Special Tool(s)

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Vehicles with manual transaxle





1. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.

CAUTION: Loosen the bolts evenly to prevent pressure plate damage.

Remove the bolts, clutch pressure plate and clutch disc.





2. Remove the starter motor isolator.





3. Remove the bolts and the flywheel.

Vehicles with automatic transaxle





4. Remove the bolts and the flexplate.

All vehicles
5. Mount the engine on a suitable stand.





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





7. Remove the bolt and the generator cooling duct.





8. Remove the nut and disconnect the generator electrical connections.





9. Remove the bolt and the generator cover.





10. Remove the bolts and the generator.





11. Remove the bolts and the accessory drive belt tensioner.





12. Loosen the bolt and remove the accessory drive belt Idler pulley.





13. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.





14. Remove the bolts and the coolant pump pulley.





15. Remove the bolts and the coolant pump.





16. Remove the engine vacuum tube.
^ Detach the 2 engine vacuum tube retainers.
^ Disconnect and remove the engine vacuum tube.





17. Detach the 2 wiring harness retainers and position the harness aside.





18. Disconnect the oil cooler hoses.





19. Remove the bolts and the thermostat housing assembly.





20. Remove the bolts and the oil level indicator.





21. Disconnect the oil pressure sensor electrical connector.





22. Remove the oil filter, 4 bolts and the oil filter adapter.
^ Discard the oil filter and Casket.

23. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler.
^ Discard the oil cooler.





24. If equipped, remove the bolt and capacitor.





25. Detach the 2 wiring harness retainers.





26. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.





27. Disconnect the temperature manifold absolute pressure (TMAP) electrical connector.





28. Disconnect the idle air control (IAC) motor electrical connector.





29. Disconnect the swirl control valve electrical connector.





30. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.





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





32. NOTE: There are 3 different size bolts used. Mark the location of the bolts to ensure installation in the correct locations.

Remove the bolts and position the intake manifold aside.





33. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.





34. Remove the exhaust gas recirculation (EGR) tube.





35. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.