Part-1

Engine

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, may cause engine failure.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

All engines

1. Remove the 8 bolts and the flexplate.





2. Remove the spacer plate.





3. Remove the crankshaft sensor ring.





4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.





5. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

Using the Floor Crane and Engine Spreader Bar, mount the engine on a suitable engine stand.





6. Remove the 2 bolts and the Right Front Lift Eye.





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





8. Remove the LH crankcase vent tube. For additional information, refer to fuel delivery and air induction.





9. Remove the RH PCV tube. For additional information, refer to fuel delivery and air induction.





10. NOTE: LH shown, RH similar.

NOTE: Heat insulating wrap removed for clarity.

Disconnect the turbocharger pressure regulator solenoid electrical connectors.





11. NOTE: LH shown, RH similar.

NOTE: The heat insulating wrap is removed with the turbocharger bypass valve.

Disconnect the wastegate hose and the 2 vacuum hoses. Remove the turbocharger bypass valve from the bracket.





12. NOTE: LH shown, RH similar.

Remove the tie straps for the vacuum hose assembly. Remove the vacuum hose assembly.





13. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.

Using a commercially available quick disconnect tool, remove the LH turbocharger coolant supply tube.





14. Remove the 2 bolts at the LH turbocharger oil return tube.

- Remove and discard the turbocharger return tube gasket.





15. Remove the LH turbocharger bracket bolt.





16. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.

NOTE: Cylinder block side shown, turbocharger side similar.

Using a commercially available quick disconnect tool, remove the LH turbocharger coolant return tube from the cylinder block.





17. Remove the 3 bolts and the LH turbocharger.

- Discard the turbocharger exhaust manifold gasket.





18. Remove the bolt for the oil supply tube.





19. Remove the bolt and the oil turbocharger oil return tube.

- Remove and discard the O-ring seal.





20. Remove the 2 bolts and the LH turbocharger mounting bracket.





21. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.

Using a commercially available quick disconnect tool, remove the RH turbocharger coolant supply tube.





22. Remove the 2 bolts at the RH turbocharger oil return tube.

- Remove and discard the turbocharger oil return tube gasket.





23. Remove the RH turbocharger bracket bolt.





24. NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.

NOTE: Cylinder block side shown, turbocharger side similar.

Using a commercially available quick disconnect tool, disconnect the RH turbocharger coolant return tube from the cylinder block.





25. Remove the 3 bolts and the RH turbocharger.

- Discard the turbocharger exhaust manifold gasket.





26. Remove the bolt for the oil supply tube.





27. Remove the bolt and the turbocharger oil return tube.

- Remove and discard the O-ring seal.





28. Remove the 2 bolts and the RH turbocharger mounting bracket.





29. Remove the 4 bolts and the RH engine support insulator.





30. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.





31. Remove the engine oil level indicator.





32. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors.





33. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Detach the EOP switch wiring harness retainer from the cylinder head.





34.Disconnect the 3 LH ignition coil-on-plug electrical connectors.





35. Remove the nut, the bolt and the CKP heat shield.





36. Remove the wiring harness retainer stud bolt.





37. Remove the wiring harness grommet.





38. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





39. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.

40. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Disconnect the CKP wire retainer. Remove the ground stud bolt.





41. Disconnect the Knock Sensor (KS) sensor electrical connector. Disconnect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors.





42. Remove the bolt, nut and the CMP heat shield. Remove the bolt and the ground strap.





43. Disconnect the 2 RH CMP sensor and the Cylinder Head Temperature (CHT) sensor electrical connectors. Remove the ground stud bolt.





44. Disconnect the 2 RH VCT solenoid electrical connectors.





45. Disconnect the 3 RH ignition coil-on-plug electrical connectors.





46. Detach all of the wiring harness retainers from the RH valve cover and stud bolts. Remove the engine wire harness.

47. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.

- Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the crankshaft front seal lip, replace the crankshaft pulley if necessary.

- Discard the bolt.





48. Using the 3 Jaw Puller, remove the crankshaft pulley.





49. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





50. Remove the 2 bolts and the accessory drive belt tensioner.