Disassembly
1. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
2. Disconnect the EGR tube from the exhaust manifold.
3. Remove the bolt and remove the oil level indicator tube.
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
5. Disconnect the four fuel injector electrical connectors.
6. Disconnect the (A) idle air control (IAC) valve and the (B) throttle position (TP) sensor electrical connectors.
7. Disconnect the following electrical connectors:
^ Water temperature indicator sender unit.
^ Temperature gauge.
^ Ignition coil.
^ Radio interference capacitor.
^ Intake manifold runner control (IMRC).
8. Remove the fuel charging wire harness.
9. Disconnect the fuel pressure regulator vacuum hose.
10. Remove the (A) three bolts, the (B) stud, and the engine mounting bracket.
11. Remove the eight intake manifold nuts, the intake manifold, the IMRC, and the gaskets.
12. Remove the spark plug wires. Refer to Powertrain Management.
13. Remove the oil filter.
14. Remove the oil pressure switch.
15. Remove the two bolts and the generator.
NOTE: Remove the nuts evenly and sequentially.
16. Remove the eight nuts and the exhaust manifold and gasket.
17. Remove the four bolts and remove the ignition coil and radio ignition interference capacitor.
18. Remove the three bolts and the ignition coil mounting bracket assembly.
19. Remove the three bolts, the water outlet connection, the thermostat, and the gasket.
20. Remove the four spark plugs. Refer to Powertrain Management.
21. Remove the four bolts and the crankcase vent oil separator assembly.
22. Using Strap Wrench D85L-6000-A or equivalent, remove the crankshaft pulley bolt.
23. Remove the two bolts and the CKP sensor.
24. Remove the outer engine front cover.
25. Align the timing marks.
26. Loosen the timing belt tensioner bolt (1). Use an 8 mm Allen wrench and turn (2) counterclockwise 1/4 turn. Insert a 1/8 inch drill bit (3) to lock the timing belt tensioner in place. Remove the timing belt (4).
27. Remove the timing belt tensioner bolt and the timing belt tensioner.
28. Use Cam Sprocket Holding/Removing Tool T74P-6256-B or equivalent to remove the camshaft sprocket bolt and washer and the camshaft sprocket.
29. Remove the inner engine front cover.
30. Remove the three bolts and one stud and remove the water pump and gasket.
31. Remove the crankshaft sprocket (6306) and the timing belt guide.
32. Remove the three bolts and the power steering pump pulley (3A733).
33. Remove the three bolts and the power steering pump (3A674).
34. Remove the five bolts and one nut and the front engine accessory drive bracket.
35. Remove the cylinder head, and the gasket. Discard the gasket. Use proper procedure.
36. Remove the oil pump.
37. Remove the four bolts and the crankshaft rear seal retainer and gasket. Discard the gasket.
38. Inspect the top of each cylinder bore before removing the piston. If a ridge has formed at the top of the cylinder, the ridge must be removed before the piston can be removed. Remove the ridge as follows:
A) Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
B) Place a clean shop cloth over the piston head to collect cuttings.
C) Use Cylinder Ridge Reamer T64L-6011-EA and remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
39. Remove the eight connecting rod cap nuts and the four connecting rod caps.
40. Install a short length of rubber tubing over the connecting rod bolts to avoid damage to the crankshaft journals.
41. Remove the pistons and the connecting rod assemblies.
NOTE: The crankshaft main bearings and connecting rod bearings are precision selective fit. Check the bearing clearances.
42. Remove the six crankshaft main bearing cap bolts and the four studs, the five main bearing caps, and the lower crankshaft main bearings.
43. Remove the crankshaft.
44. Remove the (A) upper crankshaft main bearings and the (B) crankshaft thrust main bearing (6337).