Part 1

Engine


















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

NOTICE: If the fuel rail is used as a leverage device, it may be damaged. Care must be taken when working around the fuel rail.

NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or foreign material. Remove all caps, tape and other protective materials prior to installation.

NOTE: For additional information, refer to the exploded views under Engine Engine - Assembly in the Assembly.

1. Remove the 8 bolts and the flexplate.
- Discard the bolts.





2. Remove the spacer plate and the flexplate spacer.

3. NOTE: The original crankshaft rear seal does not have a metal speedy sleeve. Replacement crankshaft rear seals come with a speedy sleeve. If present, this sleeve must be removed before attempting to remove the seal.

If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.





4. Install the engine on a suitable stand. Remove the engine lifting equipment and the Engine Lifting Brackets.

5. Remove the bolt.





6. Disconnect the A/C compressor electrical connector and wire harness retainer.





7. Remove the 4 bolts and the A/C compressor and power steering pump bracket.





8. Remove the nut and disconnect the generator B+ cable and the electrical connector and detach the wiring harness retainer.





9. Remove the generator mounting bracket.

1. Remove the bolt and the drive belt tensioner.

2. Remove the 3 generator mounting bracket bolts.





10. Disconnect the heater hose from the thermostat housing.





11. Disconnect the hose from the oil cooler.





12. Remove the bolt, the heater hose tube bracket and the hoses as an assembly.





13. NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Using the Spark Plug Wire Remover, disconnect the spark plug wires from the spark plugs.





14. Detach the RH spark plug wire retainers.





15. Detach the LH spark plug wire retainers.





16. NOTE: RH spark plug wires removed for clarity.

Disconnect the coil and the radio interference capacitor electrical connectors and detach the wiring harness retainer.





17. Remove the 2 bolts. Remove the coil, bracket and spark plug wires as an assembly.





18. Remove the oil cooler hose bracket bolt, if equipped. Disconnect the oil cooler or heater hose.





19. If equipped, remove the oil cooler and hose.





20. Disconnect the vacuum and PCV hoses from the intake manifold.





21. Disconnect the Knock Sensor (KS) electrical connector.
- Detach the wiring harness pin-type retainer.





22. Disconnect the EGR system module vacuum hose and electrical connector. Detach the wiring harness pin-type retainer.





23. Disconnect the Electronic Throttle Body (ETB) and Throttle Position (TP) sensor electrical connectors. Remove the nut and detach the wiring harness bracket.





24. Remove the exhaust manifold-to-EGR system module tube.





25. 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.

Remove the 8 bolts and the intake manifold and 6 gaskets.





26. Disconnect the 6 fuel injector electrical connectors and detach the wiring harness retainers.





27. Disconnect the Crankshaft Position (CKP) sensor electrical connector and the wiring anchors. Discard the wiring anchors.





28. Disconnect the fuel rail pressure and temperature sensor and the Camshaft Position (CMP) sensor electrical connectors.





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





30. Remove the engine wiring harness retainer bolt and remove the engine wiring harness.





31. Disconnect the fuel pressure and temperature sensor vacuum hose fitting.
- Remove the vacuum harness.





32. Disconnect the Engine Oil Pressure (EOP) switch electrical connector, remove the nut and detach the battery cable and harness bracket.





33. Detach the retainers and remove the battery cable and harness.





34. Remove the EOP switch.





35. NOTE: LH shown, RH similar.

Remove the 3 RH and the 3 LH insulator bolts and brackets.





36. Remove the fuel supply tube bolt.





37. Remove the 4 bolts and the fuel rail.





38. Remove the fuel injectors.
- Remove and discard the O-ring seals.





39. Remove the bolt and the KS.





40. Remove the thermostat housing.

1. Remove the 3 bolts.

2. Release the bypass hose clamp and remove the thermostat housing.





41. NOTE: RH shown, LH similar.

Loosen the 12 bolts and remove the valve covers.





42. Remove the bolt and the oil level indicator tube.





43. Remove the 6 nuts and the RH exhaust manifold and gasket.
- Discard the nuts and the gasket.





44. Remove and discard the 6 RH exhaust manifold studs.





45. Remove the 6 nuts and the LH exhaust manifold and gasket.
- Discard the nuts and the gasket.





46. Remove and discard the 6 LH exhaust manifold studs.





47. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the up position.





48. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the Valve Spring Compressor, remove the camshaft roller followers.





49. NOTE: Mark each hydraulic lash adjuster to make sure it is installed in its original position.

Remove the hydraulic lash adjuster.





50. Remove the RH hydraulic chain tensioner.