Part 1
Engine
Special Tool(s)
Material
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.
1. Remove the bolts and the flywheel.
2. Using the special tools, remove the crankshaft rear seal.
3. Mount the engine on a suitable stand.
4. Remove the bolts and the coolant pump pulley.
5. Remove the accessory drive belt idler pulley.
6. Disconnect the generator.
^ Remove the B+ wire terminal.
^ Disconnect the generator electrical connector.
7. Remove the bolts and the generator.
8. Remove the bolt and the coolant pump extension tube and bracket.
9. Remove the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.
^ Remove the bolts.
10. Remove the bolts and the A/C compressor bracket.
11. NOTE: Remove and discard the coolant pump outlet tube O-ring.
Remove the coolant pump outlet tube.
^ Disconnect the 3 coolant hoses.
Reposition the clamps.
^ Remove the 2 bolts and the coolant pump outlet Lube.
12. Remove the bolts and the accessory drive belt tensioner.
13. Remove the bolts and the power steering pump bracket.
14. Disconnect the crankshaft position (CKP) sensor electrical connector.
15. Remove the catalyst monitor sensor electrical connector mounting bracket.
16. Remove the bolts and the RH engine mount bracket.
17. Disconnect the oil pressure sensor electrical connector and remove the engine harness retainer.
18. Disconnect the camshaft position (CMP) sensor electrical connector.
19. Disconnect the intake manifold runner control (IMRC) electrical connector.
20. Disconnect the crankcase vent hose valve electrical connector and quick-disconnect the crankcase vent hose.
21. Disconnect the quick disconnect crankcase vent hose from the intake manifold and remove.
22. Remove the bolt and the oil level indicator and tube.
23. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
Disconnect and remove the spark plug wires and retainers as an assembly.
24. Remove the 4 engine harness pin-type retainers.
25. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
26. Disconnect the following.
1. Idle air control (IAC) electrical connector
2. Throttle position (TP) sensor electrical connector
3. Exhaust gas recirculation (EGR) system module electrical connector
4. EGR system module vacuum connector
5. EGR system module-to-exhaust manifold tube upper fitting
27. Loosen the nut and remove the EGR system module-to-exhaust manifold Lube.
28. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.
29. Remove the 3 bolts and the ignition coil.
30. Disconnect the 2 vacuum harness connections and remove the vacuum harness from the engine.
31. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.
32. Remove the upper intake manifold and discard the gaskets.
33. Remove the bolts and the fuel supply manifold, fuel injectors and fuel charging harness as an assembly.
34. Remove the fuel injector clips and fuel injectors.
35. Remove and discard the fuel injector O-rings.
36. NOTE: Record the location of the 6 long bolts and the 8 short bolts.
Remove the bolts and the lower intake manifold assembly.
37. Remove and discard the lower intake manifold sealing components.
38. Remove the nuts and the heat shield.
39. Remove the nuts and the RH exhaust manifold.
40. Remove the nuts and the LH exhaust manifold.
41. Clean and inspect the exhaust manifolds.
42. Remove the LH valve cover.
1. Remove the bolts.
2. Remove the stud bolts.
3. Remove the LH valve cover.
43. Remove the RH valve cover.
1. Remove the bolts.
2. Remove the stud bolts.
3. Remove the RH valve cover.
CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
44. NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.
Remove the rocker arms.
1. Remove the bolts.
2. Remove the rocker arms and pivots.
45. NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.
Remove the push rods.
46. Remove the lower exhaust manifold studs from both cylinder heads.
47. NOTE: Record the location of long and short bolts.
Remove and discard the cylinder head bolts.
48. NOTE: RH shown, LH similar.
Remove the RH and LH cylinder heads and the gaskets. Discard the gasket.
49. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remaining.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.