Part 1

Engine














NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

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.

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

1. NOTE: Do not reuse the flexplate bolts.
Install the Flywheel Holding Tool and remove the 6 bolts and the flexplate.

- Discard the bolts.

- Mount the engine on a suitable Engine Stand.






2. Loosen the turbocharger outlet tube clamp.





3. Remove the 2 bolts and the turbocharger outlet tube.





4. Loosen the turbocharger inlet tube clamp.





5. Remove the engine appearance cover mounting stud and position the EVAP (Evaporative Emission) canister purge valve aside.





6. Remove the bolt, stud bolt and the turbocharger inlet tube.





7. Remove the 2 turbocharger coolant tube banjo bolts and discard the gaskets.
- Loosen the 2 clamps and remove the turbocharger coolant tube.






8. Disconnect the 2 turbocharger control vacuum hoses and 2 electrical connectors.





9. Loosen the clamps and disconnect the 2 turbocharger control vacuum hoses.





10. NOTE: Do not reuse the turbocharger oil supply tube/gaskets, new parts must be installed.
Remove the 2 banjo bolts and the turbocharger oil supply tube.

- Discard the turbocharger oil supply tube and gaskets.






11. Remove and discard the turbocharger oil filter.





12. NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed.
Remove the 4 bolts and the turbocharger oil return tube.

- Discard the turbocharger oil return tube and gaskets.






13. Remove the 2 bolts and the turbocharger heat shield.





14. Remove the 4 nuts and the turbocharger.
- Discard the nuts.






15. Remove and discard the turbocharger gasket and the 4 turbocharger-to-cylinder head studs.





16. Slide the insulator up and disconnect the CHT (Cylinder Head Temperature) sensor electrical connector.
- Detach the wiring harness retainer.

- Disconnect the ECT (Engine Coolant Temperature) sensor electrical connector.

- Remove the bolt and the ground wire.






17. Disconnect the CKP (Crankshaft Position) sensor electrical connector.
- Detach the 2 wiring harness retainers.

- Remove the nut and the ground strap.






18. Remove the 2 bolts and the RH halfshaft bracket.





19. Remove the 2 bolts and the accessory drive belt tensioner.
- Remove the accessory drive belt.






20. Remove the 3 bolts and the power steering pump.





21. Remove the 3 bolts and the coolant pump pulley.
- Remove the 4 bolts and the power steering pump bracket.

- Remove the 3 bolts and the generator.






22. Remove the 3 bolts and the coolant pump.
- Remove the bolt, the nut and the idler pulley and bracket assembly.






23. Disconnect the EVAP (Evaporative Emission) tube quick connect coupling.
- Detach the heater hose retainer from the intake manifold.

- Loosen the clamp and remove the heater hose.

- Loosen the clamp and remove the CAC (Charge Air Cooler) outlet tube.






24. Disconnect the EOP (Engine Oil Pressure) switch electrical connector.
- Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.







25. Disconnect the EVAP (Evaporative Emission) tube quick connect coupling.
- Detach the 2 EVAP (Evaporative Emission) tube retainers.






26. Disconnect the EVAP (Evaporative Emission) canister purge valve electrical connector.
- Remove the EVAP (Evaporative Emission) canister purge valve and tube assembly.






27. Disconnect the 2 brake vacuum tube quick connect couplings.
- Depress the quick release locking ring and pull the brake vacuum tube out of the intake manifold quick connect fitting.






28. Disconnect the MAP (Manifold Absolute Pressure) sensor, the FRP (Fuel Rail Pressure) sensor and fuel charge harness electrical connectors.





29. Disconnect the 2 vacuum hoses from the intake manifold.
- Detach the vacuum tube retainer from the intake manifold.






30. Remove the 5 intake manifold bolts and position the intake manifold toward the cooling fan.





31. Disconnect the TB (Throttle Body) electrical connector and detach the wiring harness retainer from the TB (Throttle Body).
- Detach the 2 KS (Knock Sensor) wiring harness retainers from the intake manifold.

- Disconnect the PCV hose and remove the intake manifold.






32. Disconnect the 2 KS (Knock Sensor) electrical connectors.
- Remove the 2 bolts and the 2 KS (Knock Sensor).

- Detach the 2 wiring harness retainers.






33. Remove the 8 bolts and the crankcase vent oil separator.
- Loosen the 2 clamps and remove the coolant bypass hose.






34. Disconnect the 4 fuel injector electrical connectors and remove the fuel charge wiring harness.





35. Remove the 2 pin-type retainers and the fuel rail insulator.