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, can cause engine failure.

NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.

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

1. Remove the engine.

2. NOTE: The flexplate bolts are torque-to-yield design and are not reusable.

Remove the 8 bolts and the flexplate.

- Discard the bolts.





3. Remove the engine separator plate.





4. NOTE: Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be discarded.

Remove the crankshaft sensor ring.





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





6. Mount the engine on a work stand.

7. Remove the 3 bolts and the LH engine support insulator bracket.





8. Remove the 3 bolts and the RH engine support insulator.





9. Remove the 3 bolts and the RH exhaust manifold heat shield.





10. Remove the 8 nuts and the RH exhaust manifold.

- Discard the gasket.





11. Remove and discard the 8 RH exhaust manifold studs.





12. Remove the 3 bolts and the LH exhaust manifold heat shield.





13. Remove the 8 nuts and the LH exhaust manifold.

- Discard the gasket.





14. Remove and discard the 8 LH exhaust manifold studs.





15. Clean and inspect the RH and LH exhaust manifolds.

16. NOTE: RH shown, LH similar.

Disconnect the 8 ignition coil electrical connectors.





17. NOTE: RH shown, LH similar.

NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. RH shown, LH similar.

Remove the 8 bolts and the 8 ignition coils.





18. Disconnect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.

- Detach the 10 wiring harness retainers from the RH valve cover.





19. Disconnect the 2 VCT variable force solenoid electrical connectors.

- Detach the 10 wiring harness retainers from the LH valve cover.





20. Remove the bolt, stud bolt and heat shield from the RH cylinder head.





21. Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.

- Remove the 2 bolts and the RH intake and exhaust CMP sensors.





22. Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor electrical connectors.





23. Remove the 2 bolts and the heat shield from the LH cylinder head.





24. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.

- Remove the 2 bolts and the LH intake and exhaust CMP sensors.





25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness retainers.





26. Detach the wiring harness retainer from the engine front cover stud bolt.





27. Remove the nut and the ground wire from the engine front cover stud bolt.





28. Disconnect the 2 Knock Sensor (KS) electrical connectors.

- Remove the wiring harness from the engine.





29. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Loosen the 14 fasteners and remove the RH valve cover and gasket.

- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





30. Remove the oil level indicator.

31. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Loosen the 14 fasteners and remove the LH valve cover and gasket.

- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





32. NOTE: RH shown, LH similar.

Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.

- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).





33. NOTE: RH shown, LH similar.

Inspect the spark plug tube seals. Remove any damaged seals.

- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





34. Remove the 2 bolts and position the thermostat housing and lower radiator hose aside.

- Remove and discard the thermostat housing O-ring seal.





35. Release the 2 clamps and disconnect the coolant hoses from the oil cooler.





36. Loosen the 4 coolant pump pulley bolts.





37. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.





38. NOTE: Early build vehicles are not equipped with an A/C compressor belt tensioner. On these vehicles, the A/C compressor belt must be cut and discarded.

Rotate the A/C compressor belt tensioner clockwise and remove the A/C compressor belt.





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





40. Remove the 4 bolts and the coolant pump.

- Remove and discard the O-ring seal.





41. Remove the bolt and the accessory drive belt tensioner.





42. Disconnect the A/C compressor electrical connector and the 2 wiring harness retainers.





43. Detach the 3 wiring harness retainers.





44. Remove the 2 bolts and the generator.





45. Remove the crankshaft pulley bolt and washer.





46. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.

- Discard the crankshaft pulley bolt.





47. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the Oil Seal Remover, remove the crankshaft front oil seal.





48. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.





49. Remove the engine front cover-to-oil filter adapter bolt.





50. Using a 10 mm (0.393 in) Hex Bit loosen the engine front cover-to-oil filter adapter jack screw.





51. Remove the 13 engine front cover bolts and the 2 stud bolts.





52. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the engine front cover.

- Remove and discard the engine front cover gaskets.

- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the mating surfaces.





53. Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.





54. Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one revolution.





55. Remove the 2 bolts and the RH primary timing chain tensioner.