Part 1

Engine








Special Tool(s)

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: 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 equipped with a manual transmission





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 bolts evenly to prevent pressure plate damage.

Remove the bolts, clutch pressure plate and clutch disc.

All vehicles





2. Install the special tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.





4. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.





5. Remove the nuts and the generator heat shield.





6. Remove the nut and disconnect the generator electrical connections and harness retainer.





7. Remove the nut and the wiring harness retainer.





8. Remove the bolts and the generator.





9. Remove the bolts and the accessory drive belt tensioner.





10. Loosen the bolt and remove the accessory drive belt idler pulley.





11. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.





12. Remove the bolts and the coolant pump pulley.





13. Remove the bolts and the coolant pump.





14. Disconnect the heater hose from the thermostat housing.





15. Remove the bolts and the thermostat housing.





16. Disconnect the oil pressure sensor electrical connector.





17. Remove the oil filter.





18. Remove the bolts and the oil filter adapter.
- Discard the gasket.





19. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.





20. Remove the lower intake manifold bolt.





21. Disconnect the Throttle Position (TP) sensor electrical connector and wiring harness pin-type retainer.





22. Disconnect the Idle Air Control (IAC) valve electrical connector and wiring harness pin-type retainer





23. Disconnect the fuel rail pressure and temperature sensor vacuum hose.





24. Detach the wiring harness pin-type retainer.





25. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.





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

2.0L engines





27. If equipped, disconnect the Secondary Air Injection (AIR) vacuum supply hose.





28. Disconnect the swirl control valve electrical connector.





29. Remove the bolt and the oil level indicator tube.





30. NOTE: There are three different size bolts used. Mark the location of the bolts to ensure installation in the correct location.

Remove the seven intake manifold bolts.

2.3L engines





31. Disconnect the swirl valve electrical connectors and pin-type retainers.





32. Remove the bolts and the oil level indicator.





33. NOTE: There are three different size bolts used. Mark the location of the bolts to ensure installation in the correct location.

Remove the seven intake manifold bolts.

All engines





34. Disconnect the Positive Crankcase Ventilation (PCV) hose and remove the intake manifold.





35. Remove the Exhaust Gas Recirculation (EGR) tube.