Part 1

Engine








Special Tool(s)





Material

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

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.

NOTE: The flexplate, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.





1. Remove the bolts and the flexplate.





2. Using the special tools, remove the crankshaft rear oil slinger.





3. Using the special tools, remove the crankshaft rear seal.





4. Remove the bolts and the crankshaft rear seal retainer plate.

CAUTION: 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.

Clean and inspect the sealing surfaces.
5. Mount the engine on a suitable work stand.





6. Remove the special tool.





7. Disconnect the RH camshaft position (CMP) sensor electrical connector.





8. Remove the nut and the upper radiator hose support bracket.





9. Remove the stud bolt and the RH radio ignition interference capacitor.





10. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.





11. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.





12. Disconnect the electrical connector retainer from the coolant tube.





13. Disconnect the 4 RH ignition coil electrical connectors.





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





15. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.





16. Disconnect the LH VCT solenoid electrical connector.





17. Disconnect the oil pressure sensor electrical connector.





18. Disconnect the LH CMP sensor electrical connector.





19. Remove the stud bolt and the LH radio ignition interference capacitor.





20. Disconnect the 4 LH ignition coil electrical connectors.





21. NOTE: LH shown, RH similar.

Remove the 8 bolts and the 8 ignition coils.





22. Disconnect the crankshaft position (CKP) sensor electrical connector.
23. Remove the engine wiring harness from the engine assembly.





24. Remove the 2 bolts and the 2 knock sensors (KS).





25. Remove the stud bolt and the coolant tube.
- Discard the O-ring seal.





26. Remove the bolt and the oil level indicator lube.
- Discard the O-ring seal.





27. Remove the bolt and the RH CMP sensor.





28. Remove the bolt and the LH CMP sensor.





29. Remove the bolt and the CKP sensor.





30. CAUTION: 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.

CAUTION: When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

NOTE: The bolts are part of the valve cover and should not be removed.

NOTE: LH shown, RH similar.

Remove the bolts and the valve covers.
- Fully loosen the bolts and remove the valve cover.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





31. Remove the bolts and the RH engine support insulator.





32. Remove the 8 nuts and the RH exhaust manifold.
- Discard the gasket.





33. Remove the bolts and the LH engine support insulator.





34. Remove the 8 nuts and the LH exhaust manifold.
- Discard the gasket.





35. Remove the bolts and the oil filter adapter.
6 Discard the gasket.





36. Remove the bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.





37. Remove the bolts and the accessory drive belt tensioner.





38. Remove the bolts.





39. Remove the coolant pump from the cylinder block.
- Discard the O-ring seal.





40. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.





41. Using the special tool, remove the crankshaft seal.





42. Remove the bolts, oil pan and oil pan gasket.

CAUTION: 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. Clean and inspect the sealing surfaces.





43. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Remove the fasteners.





44. Remove the engine front cover from the cylinder block.





45. Remove the crankshaft sensor ring from the crankshaft.





46. Position the crankshaft keyway at the 12 o'clock position.





47. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.





48. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove only the 3 roller followers shown in the illustration from the RH cylinder head.





49. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.

NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the RH cylinder head.





50. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove only the 3 roller followers shown in the illustration from the LH cylinder head.





51. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the special tool, remove the 3 designated roller followers in the previous step from the LH cylinder head.





52. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.





53. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the bolts, the LH timing chain tensioner and tensioner arm.





54. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the bolts, the RH timing chain tensioner and tensioner arm.