Part 1

Engine

Disassembly (Steps 1-41)









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 may 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.

NOTE: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

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

1. Remove the 6 bolts and the flywheel.





2. Mount the engine on a suitable stand.
3. Disconnect the crankshaft position (CKP) sensor electrical connector.





4. Remove the bolt and the engine wiring harness connector bracket.





5. Detach the engine wiring harness pin-type retainer.





6. Remove the 3 bolts and the accessory drive belt tensioner.





7. Remove the 2 bolts and the oil level indicator tube.





8. Disconnect the throttle body electrical connector.





9. Disconnect the upper coolant hose from the throttle body.





10. Disconnect the lower coolant hose from the throttle body.





11. Disconnect the evaporative emissions (EVAP) tube quick connect coupling from the intake manifold.





12. Disconnect the engine oil pressure (EOP) switch electrical connector.





13. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.





14. Disconnect the knock sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.





15. Disconnect the 4 fuel injector electrical connectors and the radio capacitor electrical connector.





16. Detach all the wire harness pin-type retainers from the intake manifold.
17. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.





18. NOTE: There are 2 different size bolts used. Mark the location of the bolts to make sure of installation in the correct locations.

Remove the 8 bolts and position the intake manifold aside.





19. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Disconnect the PCV hose and remove the intake manifold.





20. Remove the EGR tube.





21. Remove the nut and the radio capacitor.





22. Remove the 2 stud bolts and the fuel rail with the fuel injectors.





23. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





24. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.





25. Disconnect the EGR valve electrical connector.
^ Remove the engine control wiring harness from the engine.





26. Remove the 3 bolts and the coolant pump pulley.





27. Remove the 3 bolts and the coolant pump.





28. Disconnect the coolant hose.





29. Remove the 3 bolts and the thermostat housing.





30. Disconnect the coolant hose.





31. Remove the bolt and the knock sensor (KS).





32. Remove the 8 bolts and the crankcase vent oil separator.





33. Remove the 4 bolts and the oil filter adapter.
^ Discard the gasket.





34. Disconnect and remove the coolant hoses.





35. If equipped, remove the block heater.





36. Remove the engine cover studs.





37. Remove the crankcase vent tube and the coil-on-plugs.





38. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.

Remove the spark plugs and the CHT sensor.
^ Discard the CHT sensor.





39. Remove the bolts and the valve cover.





40. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
^ The hole in the crankshaft pulley should be in the 6 o'clock position.





41. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Install the special tool in the slots on the rear of both camshafts.