Part 1

Engine

Special Tool(s):

Material:

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.





1. Remove the 6 bolts and the flywheel.





2. Using the special tools, remove the crankshaft rear seal.
3. Mount the engine on a suitable stand.





4. Remove the 4 bolts and the coolant pump pulley.





5. Remove the accessory drive belt idler pulley.





6. Disconnect the generator.
^ Remove the B+ wire terminal.
^ Disconnect the generator electrical connector.





7. Remove the 3 bolts and the generator.





8. Remove the bolt and the coolant pump extension tube and bracket.





9. Remove the 4 bolts and the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.





10. Remove the 4 bolts and the A/C compressor bracket.

11. NOTE: Remove and discard the coolant pump outlet tube O-ring.





Remove the coolant pump outlet tube.
^ Disconnect the 3 coolant hoses.
- Reposition the clamps.
^ Remove the 2 bolts and the coolant pump outlet tube.





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





13. Remove the 4 bolts and the power steering pump bracket.





14. Disconnect the crankshaft position (CKP) sensor electrical connector.





15. Remove the catalyst monitor sensor electrical connector mounting bracket.





16. Remove the 4 bolts and the RH engine mount bracket.





17. Disconnect the oil pressure sensor electrical connector and remove the engine harness pin-type retainer.





18. Disconnect the camshaft position (CMP) sensor electrical connector.





19. Disconnect the intake manifold runner control (IMRC) electrical connector.





20. Disconnect the crankcase vent hose valve electrical connector and quick-connect the crankcase vent hose.





21. Disconnect the quick, connect crankcase vent hose from the intake manifold and remove.





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

23. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.





Disconnect and remove the spark plug wires and retainers as an assembly.





24. Remove the 4 engine harness pin-type retainers.





25. Disconnect the knock sensor (KS) electrical connector.





26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.





27. Disconnect the following.
1 Idle air control (IAC) electrical connector
2 Throttle position (TP) sensor electrical connector
3 Exhaust gas recirculation (EGR) system module electrical connector
4 EGR system module vacuum connector
5 EGR system module-to-exhaust manifold tube upper fitting





28. Detach the wire retainer from the TP sensor stud bolt.





29. Loosen the nut and remove the EGR system module-to-exhaust manifold tube.





30. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.





31. Remove the 3 bolts and the ignition coil.





32. Disconnect the vacuum harness connection and remove the vacuum harness from the engine.





33. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.





34. Remove the upper intake manifold and discard the gaskets.





35. Remove the bolts and the fuel rail, fuel injectors and fuel charging harness as an assembly.





36. Remove the fuel injector clips and fuel injectors.





37. Remove and discard the fuel injector O-rings.

38. NOTE: Record the location of the 6 long bolts and the 8 short bolts.





Remove the bolts and the lower intake manifold assembly.





39. Remove and discard the lower intake manifold sealing components.





40. Remove the 3 nuts and the heat shield.





41. Remove the 6 nuts and the RH exhaust manifold.





42. Remove the 6 nuts and the LH exhaust manifold.
43. Clean and inspect the exhaust manifolds.





44. Remove the LH valve cover.
1 Remove the 3 bolts.
2 Remove the 2 stud bolts.
3 Remove the LH valve cover.





45. Remove the RH valve cover.
1 Remove the 3 stud bolts.
2 Remove the 2 bolts.
3 Remove the RH valve cover.

CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.

46. NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.





Remove the rocker arms.
1 Remove the bolts.
2 Remove the rocker arms and pivots.

47. NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.





Remove the 12 push rods.





48. Remove the lower 3 exhaust manifold studs from both cylinder heads.

49. NOTE: Record the location of long and short bolts.





Remove and discard all the cylinder head bolts.

50. NOTE: RH shown, LH similar.