Steps 1 - 50

DISASSEMBLY

Engine

Special Tools And Equipment, Part 1:

Special Tools And Equipment, Part 2:

Special Tools

General Equipment:

General Equipment

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

CAUTION: If the fuel rail is used as a leverage device, it can be damaged. Care must be taken when working around the fuel rail.

NOTE: During the repair or replacement of fuel related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.

NOTE: For additional information, refer to the exploded views.

All engines

1. Remove the bolts and the flexplate.
2. Remove the spacer plate and the flexplate spacer.
3. Install the engine on a suitable stand.

4. Remove the nuts and the A/C hose.

5. Remove the bolts.

6. Disconnect the A/C compressor electrical connector and wire harness retainer.

7. Remove the bolts and the accessory bracket.

8. Disconnect the generator electrical connectors and wire harness retainer.

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

10. Disconnect the following electrical connectors:
^ Camshaft Position (CMP) sensor.
^ Ignition coil.
^ Engine Coolant Temperature (ECT) sensor.
^ Ignition radio interference capacitor.
^ Fuel pressure and temperature sensor.

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

NOTE: RH shown; LH similar.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal.

Mark spark plug wire locations before removing them. Remove the spark plug wires.

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

Engines equipped with an engine oil cooler

13. Remove the oil cooler hose bracket bolts.

14. Remove the oil cooler and hoses.

All engines

15. Position aside the fuel tube.

16. Disconnect the Knock Sensor (KS) electrical connector.
^ Detach the wiring harness pin type retainer.

17. Disconnect the electronic throttle body and Throttle Position (TP) sensor electrical connectors.

18. Disconnect the Exhaust Gas Recirculation (EGR) system module vacuum hose and electrical connector.
^ Detach the wiring harness pin type retainer.

19. Remove the bolts and the intake manifold and gaskets.

20. Disconnect the 6 fuel injector electrical connectors.

21. Disconnect the Crankshaft Position (CKP) sensor electrical connector and the wiring anchors. Discard the wiring anchors.

22. Remove the engine wiring harness retainer bolts.

23. Remove the engine wiring harness.

24. Disconnect the fuel pressure and temperature sensor vacuum hose fitting.
^ Remove the vacuum harness.

25. Disconnect the oil pressure switch electrical connector and remove the battery cable and harness.

26. Remove the oil pressure switch.

27. NOTE: LH shown; RH similar.

Remove the RH and the LH insulator bolts and brackets.

28. Remove the bolts and the fuel rail.

29. Remove the fuel injectors.
^ Remove and discard the O-ring seals.

30. NOTE: RH shown; LH similar.

Loosen the bolts and remove the valve covers.

31. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp and remove the thermostat housing.

32. Remove the bolt and the oil level indicator tube

33. Remove the bolt and the Knock Sensor (KS).

34. Remove the bolts and the RH exhaust manifold and gasket.

35. Remove the bolts and the LH exhaust manifold and gasket.

36. Using the special tool to hold the crankshaft pulley, remove the bolt.

37. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.

Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the 2 8 mm bolts, remove the crankshaft pulley.
^ Discard the crankshaft pulley bolt.

38. Remove the bolts and the coolant pump pulley.

39. Remove the bolts and the coolant pump.

40. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the UP position.

41. 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.