Part 1

Engine

Special Tool(s):

Special Tool(s):

Material:

Disassembly (Steps 1-38)

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. 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 crankshaft rear seal, the rear oil seal slinger and the crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.





1. Remove the 6 bolts and the flexplate.





2. Remove the engine/transmission spacer plate.





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





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





5. Remove the 2 oil pan-to-crankcase rear seal retainer plate bolts and the 6 crankcase rear seal retainer plate bolts.





6. Mount the engine on a suitable engine stand.

7. NOTE: RH shown, LH similar.





Remove the LH and the RH engine mount.

8. NOTE: LH shown, RH similar.





Remove the drain plugs from the engine block. Allow the coolant to completely drain.
^ Install the drain plugs when finished.
^ To install, tighten to 20 Nm (15 ft. lbs.).





9. Remove the bolt and the battery cables from the engine.





10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.





11. Disconnect the 8 ignition coil electrical connectors.





12. Disconnect the 8 fuel injector electrical connectors.





13. Remove the 2 bolts and the intake manifold shield.





14. Disconnect and remove the crankcase ventilation tube.





15. Remove the 4 generator mounting bracket bolts and the bracket.





16. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.





17. Disconnect the generator electrical connector.





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





19. Remove the generator wiring harness anchor from the LH front stud.





20. Disconnect the ground wire from the RH rear stud.





21. Disconnect the camshaft position (CMP) sensor electrical connector.





22. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.





23. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.





24. Disconnect the vacuum hoses and the electrical connector.





25. Disconnect the fuel charging wiring from the intake manifold crash bracket and remove the harness from the engine assembly.





26. Disconnect the EGR tube nut from the EGR valve.





27. Remove the 2 generator bolts and the generator.





28. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





29. Remove the intake manifold crash bracket stud bolt.





30. Remove the 8 bolts and the 8 ignition coils.





31. Remove the 2 bolts and the coolant outlet adapter.





32. Remove the thermostat.





33. Remove the 8 bolts and the intake manifold.





34. Remove the intake manifold gaskets and discard.

35. 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.





Clean the sealing surfaces.





36. Remove the coolant bypass tube.
1 Remove the retaining nut.
2 Remove the ground strap.
3 Remove the coolant bypass tube.





37. Remove the 2 bolts and the knock sensor.





38. Remove the 5 studs and 5 bolts and the LH valve cover. Discard the gasket.
^ Clean the mating surface.