Part 1
Engine
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
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.
Engines with automatic transmission
1. Remove the 8 bolts and the flexplate.
Engines with manual transmission
2. NOTICE: Loosen the bolts evenly to prevent clutch pressure plate damage.
NOTE: If the parts are to be reused, index-mark the pressure plate to the flywheel.
Remove the 6 pressure plate bolts, remove the pressure plate and the clutch disc.
- Discard the pressure plate bolts.
3. NOTE: The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).
Remove the 8 bolts and the dual mass flywheel.
All engines
4. Remove the spacer plate.
5. Remove the crankshaft sensor ring.
6. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
7. 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 Spreader Bar, mount the engine on a suitable engine stand.
8. Remove the LH and RH engine lift eyes.
9. Remove the crankcase vent tube.
10. Remove the engine oil level indicator.
11. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
- Detach the EVAP (Evaporative Emission) canister purge valve electrical connector wiring harness pin-type retainer.
12. Disconnect the Throttle Body (TB) electrical connector.
- Detach the TB (Throttle Body) electrical connector wiring harness pin-type retainer from the TB (Throttle Body).
13. Disconnect the PCV tube quick connect couplings from the PCV valve and intake manifold.
14. Detach the wiring harness pin-type retainer from the rear of the upper intake manifold.
15. Remove the LH fuel rail insulator.
16. Remove the upper intake manifold support bracket bolt from the front of the RH cylinder head.
17. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
Loosen the 7 bolts and remove the upper intake manifold.
- Remove and discard the gaskets.
- Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
18. Remove the RH fuel rail insulator.
19. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
20. Disconnect the Cylinder Head Temperature (CHT) sensor wiring harness jumper electrical connector.
21. Disconnect the 3 RH fuel rail electrical connectors.
22. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
23. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
24. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Detach the EOP (Engine Oil Pressure) switch wiring harness retainer from the cylinder head.
26. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
27. Disconnect the 3 LH fuel rail electrical connectors.
28. Disconnect the 2 LH VCT (Variable Camshaft Timing) solenoid electrical connectors.
29. Disconnect the Knock Sensor (KS) sensor electrical connector.
30. Disconnect the 2 LH CMP (Camshaft Position) sensors electrical connectors.
- Detach the wiring harness retainer from the rear of the cylinder head.
31. Remove the nut, the bolt and the heat shield.
32. Remove the wiring harness retainer stud bolt.
33. Remove the wiring harness grommet.
34. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
35. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
36. Remove the nut, bolt and the generator.
- Remove the generator stud.
37. 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.
38. Using the 3 Jaw Puller, remove the crankshaft pulley.
39. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
40. Remove the 2 bolts and the accessory drive belt tensioner.
41. Remove the LH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.
42. Remove the RH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.
43. Remove the heater tube bolt.
44. Detach the heater tube retainer from the RH valve cover stud bolt.
45. Remove the 4 bolts and the thermostat housing.
- Discard the thermostat housing and coolant inlet tube O-ring seals.
46. Remove the 4 bolts and the coolant pump pulley.
47. Remove the 7 bolts and the coolant pump.
- Discard the coolant pump gasket and coolant pump O-ring seal.
48. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 LH ignition coil-on-plugs.
49. NOTICE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
Remove the 3 LH spark plugs.
50. NOTICE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
NOTICE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT (Variable Camshaft Timing) seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT (Variable Camshaft Timing) seal and VCT (Variable Camshaft Timing) oil control solenoid may occur.
NOTE: The plastic electrical connector on the VCT (Variable Camshaft Timing) oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.
Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.
- Discard the gasket.
51. Inspect the 2 VCT (Variable Camshaft Timing) solenoid seals. Remove any damaged seals.
- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
52. Inspect the spark plug tube seals. Remove any damaged seals.
- Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Remover and Handle, remove the seal(s).
53. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
54. Remove the 2 bolts and the LH exhaust manifold heat shield.
55. Remove the 6 nuts and the LH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.
56. Clean and inspect the LH exhaust manifold.
57. Remove and discard the 6 LH exhaust manifold studs.
58. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 RH ignition coil-on-plugs.
59. NOTICE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
Remove the 3 RH spark plugs.