Steps 1-45

Engine





NOTICE: 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 the pulley bolt is loosened. 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.

NOTICE: 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: For additional information, refer to the exploded views under the Engine Assembly procedure.

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 this instruction may result in serious personal injury.

NOTICE: Loosen the 6 bolts evenly to prevent pressure plate damage.

Remove the 6 bolts, clutch pressure plate and clutch disc.





2. Remove the 6 bolts and the flywheel.





Vehicles with automatic transaxle

3. Remove the 6 bolts and the flexplate.





All vehicles

4. Mount the engine on a suitable Engine Stand.

5. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the engine.





6. Remove the 2 bolts and the tensioner.





7. Remove the bolt and the accessory drive belt idler pulley.





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





9. Remove the 3 bolts and the coolant pump.
- Remove and discard the O-ring seal.





10. Disconnect the Knock Sensor (KS) electrical connector.





11. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.





12. Disconnect the coolant hose from the EGR valve.





13. Remove the coolant tube retainer from the intake manifold.





14. Remove the 3 bolts and the thermostat housing assembly.





15. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the wiring harness pin-type retainer.





16. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector and detach the 2 wiring harness retainers from the generator stud bolts.





17. Disconnect the Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness retainer from the valve cover stud bolt.





18. Remove the 2 nuts, 1 bolt and the generator.





19. Remove the 2 generator studs.





20. Remove the 2 bolts and the exhaust flexible pipe bracket.





21. Remove the 4 exhaust manifold heat shield bolts and the heat shield.





22. Remove and discard the 7 exhaust manifold nuts.





23. Remove the exhaust manifold and discard the exhaust manifold gasket.

24. Clean and inspect the exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.

25. Remove and discard the 7 cylinder head studs.





26. Remove the bolt and the A/C manifold tube.
- Discard the 2 O-ring seals.





27. Remove the 3 bolts and the A/C compressor.





28. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.





29. Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.





30. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.





31. Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.





32. Detach the 2 wiring harness retainers from the intake manifold.





33. Disconnect the EGR valve electrical connector.





34. Disconnect the radio capacitor electrical connector.





35. Disconnect the 4 fuel injector electrical connectors.
- Detach the 2 wiring harness retainers and remove the wiring harness assembly.





36. Disconnect the 4 ignition coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.





37. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and remove the wiring harness.





38. Remove the fuel rail insulator.





39. Remove the nut and the radio capacitor.





40. Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.





41. Remove the 7 bolts (3 shown) and position the intake manifold aside.





42. 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.

Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.





43. Remove the EGR tube.





44. Disconnect the bypass hose.





45. Remove the bypass hose from the coolant outlet.