Part 1
DISASSEMBLY (Steps 1-48)
Material:
All vehicles
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 8 bolts and the flexplate.
2. Using the special tools, remove and discard the crankshaft rear oil seal.
3. Mount the engine on a suitable stand.
Freestyle only
4. If equipped, remove the 3 retainers and the A/C compressor pulley shield.
All vehicles
5. Rotate the tensioner counterclockwise and remove the accessory drive belt.
6. Disconnect the A/C compressor electrical connector.
7. Disconnect the LH catalyst monitor sensor electrical connector and detach the wiring retainer.
Freestyle only
8. If equipped, remove the 2 nuts, the bolt and the A/C compressor shield.
9. Remove the bolt and the A/C compressor.
All vehicles
10. Remove the 2 bolts, 2 nuts and the A/C compressor.
11. Remove the 5 bolts and the A/C compressor bracket.
12. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and detach the wiring retainer.
13. Disconnect the oil pressure sensor electrical connector.
14. Remove the 2 nuts, disconnect the camshaft position sensor (CMP) and detach the retainers.
15. Loosen the fittings and remove the exhaust gas recirculation (EGR) system module tube.
16. Disconnect the EGR system module electrical connector.
17. Disconnect the throttle body electrical connector.
18. Disconnect and remove the positive crankcase ventilation (PCV) tube.
19. Disconnect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
20. Disconnect the fuel charging wiring harness electrical connector.
21. Disconnect the RH HO2S and detach the retainer.
22. Remove the bolt and detach the power steering tube bracket.
23. Remove the bolt and detach the power steering tube bracket.
24. Remove the 2 nuts and detach the power steering fluid reservoir.
25. Remove the power steering fluid reservoir bracket nut.
26. Remove the 3 nuts and the power steering pump, reservoir and tubes.
27. NOTICE: If the engine is repaired or replaced because of 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 8 bolts and the upper and lower intake manifold.
^ Remove and discard the gaskets.
28. Remove the nut and position the wiring conduit aside.
29. Disconnect the RH ignition coil electrical connectors and detach the wiring retainers.
30. Remove the nut and disconnect the generator wiring.
^ Detach the wiring retainer.
31. Remove the nut and detach the ground wire.
32. Disconnect the crankshaft position sensor (CKP) electrical connector and detach the wiring retainer.
33. Disconnect the LH ignition coil electrical connectors and detach the wiring retainers.
34. Disconnect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.
35. Disconnect the bypass and the coolant pump hoses.
36. Remove the engine wiring harness.
37. Remove the stud bolt and the oil level indicator tube.
^ Remove and discard the O-ring seal.
38. Remove and discard the oil filter.
39. Remove the 4 bolts and the oil filter adapter.
^ Remove and discard the O-ring seal from the M22 bolt.
40. Remove the 2 nuts, bolt and the generator.
41. Remove the 4 bolts and the RH engine insulator bracket.
42. Remove and discard the 6 RH exhaust manifold nuts.
43. Remove the RH exhaust manifold.
^ Remove and discard the gasket.
44. Remove and discard the 6 RH exhaust manifold studs.
45. Remove and discard the 6 LH exhaust manifold nuts.
46. Remove the LH exhaust manifold.
^ Remove and discard the gasket.
47. Remove and discard the 6 LH exhaust manifold studs.
48. Remove the 6 bolts and the RH and LH ignition coils.