Part 1
Engine
Disassembly (Steps 1-32)
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
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: 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 6 bolts evenly to prevent pressure plate damage.
Remove the 6 bolts, clutch pressure plate and clutch disc.
2. Remove the starter motor isolator.
3. Remove the 6 bolts and the flywheel.
Vehicles with automatic transaxle
4. Remove the 6 bolts and the flexplate.
All vehicles
5. Mount the engine on a suitable stand.
6. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
7. Remove the accessory drive belt from the engine.
8. Remove the 2 bolts and the tensioner.
9. Disconnect the power steering pressure (PSP) switch electrical connector.
10. Remove the 2 upper power steering pump bolts.
11. Remove the lower bolt and the power steering pump.
12. Disconnect the knock sensor (KS) electrical connector and the 2 harness pin-type retainers.
13. Disconnect the lower radiator and heater hoses from the thermostat housing.
^ Detach the radiator hose retainer clip from the intake manifold.
14. Disconnect the coolant hose from the throttle body and remove the hose from the engine.
15. Disconnect the A/C compressor electrical connector.
16. Remove the bolt and the A/C manifold.
17. Remove the 3 bolts and the A/C compressor.
18. Remove the 3 bolts and the coolant pump pulley.
19. Remove the 3 bolts and the coolant pump.
^ Remove and discard the O-ring seal.
20. Remove the bolt and the accessory drive belt idler pulley.
21. Disconnect the crankshaft position (CKP) sensor electrical connector and harness pin-type retainer.
22. NOTE: Whenever the CKP sensor is removed, a new one must be installed, using the alignment jig supplied with the new part.
Remove the 2 bolts and the CKP sensor.
^ Discard the CKP sensor.
23. Remove the 2 nuts and the generator splash shield.
24. Pull back the rubber boot and remove the nut.
^ Disconnect the generator electrical connections and pin-type retainer.
25. Remove the bolt, 2 stud bolts and the generator.
Vehicles with secondary air injection (AIR)
26. Disconnect the secondary air injection (AIR) hose from the catalytic converter.
27. Disconnect the AIR valve vacuum supply tube from the intake manifold.
28. Disconnect the AIR valve electrical connector.
29. Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.
All vehicles
30. NOTE: Vehicles equipped with AIR have 2 catalyst monitor sensors (CMS).
Disconnect the CMS electrical connector(s).
31. Disconnect the heated oxygen sensor (HO2S) electrical connector.
32. Remove the wiring harness bracket from the valve cover stud.