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.

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

All engines

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 (Power Steering Pressure) switch electrical connector.





Front Wheel Drive (FWD) vehicles

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





All engines

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 (Camshaft Position) sensor electrical connector.





25. Disconnect the LH CMS (Catalyst Monitor Sensor) sensor electrical connector.





26. Disconnect the LH HO2S (Heated Oxygen Sensor) electrical connector.





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





28. Disconnect the LH VCT (Variable Camshaft Timing) 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.






40. Remove the bolt and the A/C manifold.
- Discard the O-ring seals.






41. Remove the nut, 2 bolts and the A/C compressor.





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





43. Remove the bolt, nut and the generator.





44. Detach the PSP (Power Steering Pressure) hose retainer from the engine lifting eye.





45. Remove the PSP (Power Steering Pressure) hose bracket nut.





46. Remove the PSP (Power Steering Pressure) tube bracket bolt from the RH cylinder head.





47. Remove the 3 bolts and the power steering pump.





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





49. Remove the 4 nuts (3 shown) and the LH catalytic converter.
- Discard the nuts and the gasket.






50. Remove the 3 bolts and the LH exhaust manifold heat shield.





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






52. Clean and inspect the LH exhaust manifold.

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





FWD (Front Wheel Drive) vehicles

54. Remove the 4 nuts and the RH catalytic converter.
- Discard the nuts and the gasket.






All engines

55. Remove the 3 bolts and the RH exhaust manifold heat shield.





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






57. Clean and inspect the RH exhaust manifold.

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





59. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.






60. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.






61. Remove the pin-type retainer and the cover.





62. Remove the 2 bolts and the engine lifting eye.





63. Remove the bolt and the upper intake manifold support bracket.





64. Remove the bolt and the RH CMP (Camshaft Position) sensor.





All-Wheel Drive (AWD) vehicles

65. Remove the 2 bolts and the catalytic converter bracket.





All engines

66. Remove the 4 bolts and the fuel rail and injectors as an assembly.





67. Remove the 2 thermostat housing-to-lower intake manifold bolts.
- Remove the thermostat housing and discard the gasket.






68. 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 10 bolts and the lower intake manifold.
- Discard the gaskets.






69. Disconnect and remove the CHT (Cylinder Head Temperature) sensor jumper harness.





70. Remove the bolt and the LH CMP (Camshaft Position) sensor.