Part 1

Engine

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, can cause engine failure.

NOTICE: Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

All vehicles

1. Remove the 8 bolts and the flexplate.

2. Remove the crankshaft sensor ring.

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

4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

Mount the engine on a suitable engine stand.

5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.

6. If equipped, remove the heat shield and disconnect the block heater electrical connector.

7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the Power Steering Pressure (PSP) hose.
- Remove the block heater wiring harness from the engine.

8. Disconnect the PCV hose from the PCV valve.

9. Disconnect the Throttle Body (TB) electrical connector.

10. Detach the wiring harness retainers from the upper intake manifold.

11. Remove the upper intake manifold support bracket bolt.

12. 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 6 bolts and the upper intake manifold.

- Discard the gaskets.

13. Disconnect the PSP switch electrical connector.

Front Wheel Drive (FWD) vehicles

14. Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.

All vehicles

15. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.

16. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.

17. Disconnect the 3 RH coil-on-plug electrical connectors.

18. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.

19. Disconnect the coolant bypass hose from the thermostat housing.

20. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.

21. Disconnect the Knock Sensor (KS) electrical connector.

22. Disconnect the 6 fuel injector electrical connectors (3 shown).

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

24. Disconnect the LH CMP sensor electrical connector.

25. Disconnect the LH CMS sensor electrical connector.

26. Disconnect the LH HO2S electrical connector.

27. Disconnect the 3 LH coil-on-plug electrical connectors.

28. Disconnect the LH VCT solenoid electrical connector.

29. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.

30. Remove the wiring harness retainer bolt from the rear of the LH 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. Disconnect the A/C compressor electrical connector.

36. Remove the nut and disconnect the generator B+ cable.

37. Disconnect the generator electrical connector.

38. Detach the wiring harness retainer from the generator.

39. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
- Remove the wiring harness from the engine.