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.
^ Ignition coil.
^ Intake Manifold Runner Control (IMRC).
^ Knock sensor.
^ Fuel pressure sensor.
8. Disconnect the fuel pressure sensor electrical connector.
9. Remove the fuel charging wire harness.
10. Remove the (A) bolts, the (B) stud, and the engine mounting bracket.
11. Remove the nuts, the intake manifold, the IMRC, and the gaskets.
12. Remove the spark plug wires.
13. Remove the oil filter.
14. Remove the oil pressure switch.
15. Remove the two bolts and the Generator (GEN).
16. Note: Remove the nuts evenly and sequentially.
Remove the nuts, the exhaust manifold and the gasket.
17. Remove the four bolts and remove the ignition coil and radio ignition interference capacitor.
18. Remove the bolts and the ignition coil mounting bracket assembly.
19. Remove the bolts, the water outlet connection, the thermostat, and the gasket.
20. Remove the four spark plugs.
21. Remove the four bolts and the crankcase vent oil separator assembly.
22. Use Strap Wrench to remove the crankcase pulley bolt.
23. Remove the two bolts and the CKP sensor.
24. Remove the (A) three nuts, the (B) three bolts, and the outer engine front cover.
25. Align the timing marks.
26. Remove the timing belt.
1. Use an 8 mm Allen wrench and turn counterclockwise 1/4 turn.
2. Insert a 1/8 drill bit to lock the timing belt tensioner in place.
3. Remove the timing belt.
27. Remove the (A) bolt and the (B) timing belt tensioner.
28. Use Cam Sprocket Holding/Removing Tool to remove the (A) camshaft sprocket bolt and washer and the (B) camshaft sprocket.
29. Remove the inner engine front cover.
30. Remove the bolts and the stud and the water pump and gasket.
31. Remove the crankshaft sprocket and the timing belt guide.
32. Remove the three bolts and the power steering pump pulley.
33. Remove the bolts and the power steering pump.
34. Remove the five bolts and one nut and the front engine accessory drive bracket.
35. Remove the bolts and the valve cover and gasket.
36. Note: Remove the bolts evenly and sequentially.
Remove the ten cylinder head bolts, the cylinder head, and the gasket. Discard the gasket.
37. Remove the bolts and remove the oil pan and oil pan gasket. Discard the gasket.
38. Remove the bolts and the oil pump screen cover and tube and gasket. Discard the gasket.
39. Remove the nuts and the oil baffle.
40. Remove the six bolts and the oil pump.
41. Remove the bolts and the crankshaft rear seal retainer and gasket. Discard the gasket.
42. Remove the eight connecting rod cap nuts and the four connecting rod caps.
43. Install a short length of rubber tubing over the connecting rod bolts to avoid damage to the crankcase journals.
44. 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 pistons can be removed. Remove the ridge as follows:
^ Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
^ Place a clean shop cloth over the piston head to collect cuttings.
^ Use Cylinder Ridge Reamer and remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 inch) when removing the ridge.
45. Remove the pistons and the connecting rod assemblies.
46. Note: The crankshaft main bearings are precision selective fit.
Remove the six crankshaft main bearing cap bolts and the four studs, the five main bearing caps, and the lower crankshaft main bearings.
47. Remove the crankshaft.
48. Remove the (A) upper crankshaft main bearing and the (B) crankshaft thrust main bearing.