Part 1

Engine














WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

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.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.

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

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, remove the heat shield and disconnect the block heater electrical connector.
- Detach all of the engine block heater harness retainers and remove the harness.






6. Remove the nut and the A/C tube from the compressor.
- Discard the O-ring seal and gasket seal.






7. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





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





9. Disconnect the brake vacuum tube from the intake manifold.





10. Disconnect the LH turbocharger bypass valve electrical connector.





11. NOTE: Index-mark the hoses for installation.
Remove the turbocharger wastegate regulating valve hoses from the RH CAC (Charge Air Cooler) tube and turbocharger wastegate regulating valve.






12. Loosen the clamp and remove the LH turbocharger intake tube from the LH turbocharger.





13. Disconnect the RH turbocharger bypass valve electrical connector.





14. Loosen the clamp and remove the RH CAC (Charge Air Cooler) tube from the RH turbocharger.





15. Loosen the clamp and remove the RH turbocharger intake pipe from the RH turbocharger.





16. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the nut from the RH valve cover stud bolt for the RH turbocharger intake tube.






17. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the RH CAC (Charge Air Cooler) tube nut from the intake manifold and remove the RH CAC (Charge Air Cooler) tube and turbocharger intake tube as an assembly.





18. Remove the lower radiator hose from the thermostat housing.





19. Disconnect the 2 quick connect couplings and remove the PCV tube.





20. Remove the noise insulator shield for the fuel injection fuel pump and disconnect the electrical connector.





21. Disconnect the Throttle Position (TP) sensor and electronic TB (Throttle Body) electrical connectors.





22. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.





23. Disconnect the A/C compressor electrical connector.
- Detach the wiring harness retainer from the from the A/C stud bolt.






24. Remove the A/C compressor nut and the Catalyst Monitor Sensor (CMS) electrical connector bracket.
- Detach the CMS (Catalyst Monitor Sensor) electrical connector from the bracket.






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





26. Disconnect the generator electrical connector.





27. Remove the nut, bolt and the generator.
- Remove the generator stud.






28. Remove the bolt and the A/C compressor.





29. Remove the A/C compressor mounting stud from the oil pan.





30. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Detach the EOP (Engine Oil Pressure) wiring harness retainer from the engine block.