Disassembly Special Tool(s) | Slide Hammer 205-047 | | Universal Flange Holding Wrench 205-072 | | Lifting Bracket, Engine 303-122 | | Socket, Cylinder Head Bolt 303-392 | | Locking Tool, Flywheel 303-393 | | Mounting Stand 303-435 | | Mounting Bracket for 303-435 303-435-06 | | Mounting Plate for 303-435-06 303-435-14A | | Socket, Spark Plug 303-499 | | Adapter for 205-047 303-633 | | Locking Tool, Timing Belt Tensioner 303-1054 | General Equipment Securing straps Engine hoist One bolt M10 x 40 mm One bolt M10 x 45 mm Oil filter strap wrench | -
Remove the engine wiring harness. | | -
Attach the special tool to the engine. | | -
Install the special tool. | | -
Mount the engine on the mounting stand. | | -
Drain the engine. - Allow the oil to drain into a suitable container.
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Remove the oil pressure switch. | | -
Remove the coolant pump pulley. | | -
Remove the engine front mount bracket. | | -
Remove the timing belt upper cover. | | -
Disconnect the spark plug electrical connectors and detach the spark plug wires from the valve cover. | | -
Using the special tool, remove the spark plugs. | | -
Using the special tool, lock the flywheel. | | -
Remove the crankshaft pulley. | | -
Remove the timing belt lower cover. | | -
Remove the timing belt. - Tension the timing belt tensioner by turning it and lock it in position using the special tool.
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Remove the timing belt tensioner. | | -
CAUTION:Install a hose (order no. E890438S) to the special tool studs, to prevent damage to the camshaft pulley. Using the special tool, prevent the camshaft pulley from rotating and remove the camshaft pulleys. - Discard the retaining bolts.
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Remove the crankshaft timing belt pulley. | | -
Remove the timing belt rear cover. | | -
CAUTION:Keep the camshaft bearing caps and the camshafts in order for installation. Remove the camshafts. - Slacken each camshaft bearing cap retaining bolt in the sequence shown by one turn until the camshaft is released.
- Remove the camshaft bearing caps.
- Remove and discard the camshaft seals.
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Disconnect the positive crankcase ventilation (PCV) hose from the PCV cover. | | -
Detach the oil level indicator and tube from the intake manifold. | | -
Remove the intake manifold lower retaining bolt. | | -
CAUTION:Remove the cylinder head bolts in the sequence shown. Using the special tool, remove the cylinder head. | | -
CAUTION:Do not damage the coolant pump impeller. Remove the coolant pump. | | -
Remove the thermostat housing. | | -
Remove the knock sensor (KS). | | -
Remove the the positive crankcase ventilation (PCV) cover. | | -
Remove the oil pan retaining bolts. | | -
CAUTION:In order to prevent damage to the sealing surfaces, only use the designated special tool to remove the oil pan. Do not use a chisel or screwdriver for removal. NOTE:Tighten the lock nut against the oil pan and use several taps to release the oil pan from the cylinder block. Using the special tool, remove the oil pan. | | -
Remove the oil pump pickup tube. | | -
Remove the clutch disc and pressure plate. For additional information, refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Removal and Installation). | | -
Remove the crankshaft position (CKP) sensor. | | -
Remove the CKP sensor bracket. | | -
Remove the crankshaft rear seal carrier. - Discard the crankshaft rear seal carrier.
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Remove the cylinder block (short block) from the mounting stand. - Remove the special tools.
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