Part 1

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ENGINE DISASSEMBLY - 2.3L

Part 1

Lower Engine Block










Front Engine Block










Cylinder Head










Intake Manifold










Disassembly

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





1.

CAUTION:If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch release.

NOTE:If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.

Remove the bolts, the clutch pressure plate and the clutch disc.

All vehicles





1. Install the flywheel locking tool SST and remove the flexplate.

2. Mount the engine on a suitable engine stand.






1. Remove the drive belt.






1. Remove the engine oil level indicator assembly.
a. Remove the engine oil level indicator.

b. Remove the bolts.

c. Remove the engine oil level indicator tube.






1. Remove the front coolant outlet pipe.
a. Remove the bolts.

b. Remove the water outlet tube.






1. Remove the bolts and the A/C compressor.






1.
NOTE:The generator will be removed with the front end accessory drive (FEAD) mounting bracket.Remove the FEAD mounting bracket.






1. Remove the bolts and the RH motor mount.






1. Disconnect the coolant hose from the thermostat and the coolant hose from the positive crankcase ventilation (PCV) fitting on the intake manifold.






1. Remove the coolant tube assembly.






1. Remove the exhaust manifold and gasket.






1. Remove the block heater, if equipped.






1. Remove the rear coolant outlet pipe.
a. Remove the coolant hose.

b. Remove the rear coolant outlet pipe and the mounting gasket.






1. Remove the EGR valve.
a. Disconnect the electrical connector.

b. Disconnect the coolant hose.

c. Remove the bolts and EGR valve.






1. Remove the power steering pump.






1. Disconnect the following electrical connectors:

- idle air control (IAC) valve
- throttle position (TP) sensor
- manifold absolute pressure (MAP) sensor






1. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.






1. Disconnect the knock sensor (KS) electrical connector, remove the three bolts and position the engine wiring harness and bracket aside.






1. Disconnect the camshaft position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.

2. Disconnect the engine wiring harness pin-type retainers from the intake manifold.






1. Disconnect the (EGR) tube from the intake manifold.






1. Remove the EGR tube.

- Remove the EGR tube bracket from the intake manifold.
- Disconnect the EGR tube from the cylinder head.
- Remove the EGR tube.






1. Detach the fuel supply hose clip from the front of the intake manifold.






1. Remove the intake manifold assembly.






1. Disconnect the four fuel injector electrical connectors and the two wiring harness pin-type retainers.






1. Disconnect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.






1. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.

Continued in Part 2 Part 2