Part 1

Engine













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

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

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

1. Remove the engine. For additional information, refer to Engine Engine - Removal in the Removal.

2. Remove the 8 bolts and the flexplate.





3. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.





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





5. Remove the 8 bolts and the crankshaft rear seal retainer plate.

- 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.

Clean and inspect the sealing surfaces.





6. NOTICE: Do not use the oil pan to support the engine, or oil pan and oil pan gasket damage may occur.

Lower and support the engine assembly on wood blocks.

7. Remove the Engine Lifting Bracket.





8. Install the engine assembly onto a suitable engine stand.

9. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

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

- Discard the engine support insulator bracket bolts.





10. NOTE: LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.





11. NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the engine cooling fan from the coolant pump pulley.





12. Disconnect the Camshaft Position (CMP) sensor electrical connector.





13. Remove the nut and the RH radio ignition interference capacitor.





14. Disconnect the 10 ignition coil electrical connectors.





15. Remove the 10 bolts and the 10 ignition coils.
- Remove the ignition coil by using a twisting motion while pulling up on the ignition coil.





16. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.





17. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.





18. Remove the nut and the LH radio ignition interference capacitor.





19. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





20. Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.

21. Remove the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.





22. Remove the 2 bolts and the exhaust manifold heat shield.





23. Remove the 10 nuts and the RH exhaust manifold.
- Discard the 2 gaskets and the 10 nuts.

- Inspect the exhaust manifold. For additional information, refer to Engine.





24. Remove the 3 bolts and the exhaust manifold heat shield.





25. Remove the 10 nuts and the LH exhaust manifold.
- Discard the 2 gaskets and the 10 nuts.

- Inspect the exhaust manifold. For additional information, refer to Engine.





26. NOTE: LH shown, RH similar.

Remove and discard the 20 exhaust manifold-to-cylinder head studs.





27. 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.

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

Loosen the 16 fasteners in the sequence shown 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.





28. 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.

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

Loosen the 17 fasteners in the sequence shown 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.





29. Remove the 5 bolts, the coolant pump pulley and the accessory drive belt idler pulley.





30. Remove the 3 bolts and the accessory drive belt tensioner.





31. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.





32. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.





33. Remove the front 4 oil pan bolts.





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

Remove the 15 fasteners.





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





36. NOTICE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Loosen and backoff the RH camshaft sprocket bolt one full turn.





37. NOTICE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Loosen and backoff the LH camshaft sprocket bolt one full turn.





38. NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

Using the sequence shown, remove the 6 bolts, then the 3 balance shaft bearing caps and the balance shaft.





39. Remove the crankshaft sensor ring from the crankshaft.





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