Part 2

Engine

Disassembly (Steps 37-78)





37. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.





38. Remove the 3 power steering reservoir nuts.





39. Remove the 3 bolts and the power steering pump and reservoir assembly.





40. Remove the wiring harness retainer bolt.





41. Detach the wiring harness from the cylinder block.

42. Remove the wiring harness from the engine.





43. Remove the 3 bolts and the generator.





44. Remove the 3 bolts and the A/C compressor.





45. Remove the 3 bolts and the A/C compressor bracket.





46. Remove the 6 nuts and the RH catalytic converter.
^ Discard the gasket and nuts.

47. Clean and inspect the RH catalytic convertor manifold.

All wheel drive (AWD) engines





48. Remove the 6 nuts and the RH exhaust manifold.
^ Discard the gasket and nuts.

49. Clean and inspect the RH exhaust manifold.

All engines





50. Remove and discard the 6 RH catalytic converter studs.

51. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.





52. Remove the 4 bolts and the LH heat shield.





53. Remove the 2 bolts from the LH catalytic converter bracket.





54. Remove the 6 nuts and the LH catalytic converter.
^ Discard the gasket and nuts.

55. Clean and inspect the LH catalytic converter manifold.





56. Remove and discard the 6 LH catalytic converter studs.

57. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.





58. Remove the 2 bolts and the LH catalytic converter bracket.





59. Remove the bolt and the oil level indicator tube.
^ Remove and discard the O-ring seal.





60. 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 8 bolts and the lower intake manifold.
^ Discard the gaskets.





61. Position the Stretchy Belt Remover under the coolant pump belt as shown.





62. NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley as shown.





63. Remove the coolant pump belt.
^ Fold the Stretchy Belt Remover over the top of the coolant pump belt.
^ In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine, removing the coolant pump belt.





64. Release the 2 clamps and remove the thermostat housing.





65. Remove the bolt, stud bolt and the coolant bypass.
^ Remove and discard the O-ring seals.





66. Disconnect the coolant pump hose from the cylinder block outlet.





67. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump drive pulley from the camshaft.





68. Remove the 3 bolts and the coolant pump.





69. Remove the bolt and the KS.





70. Remove the EOP switch.





71. If equipped, remove the block heater.

72. NOTE: When removing the coil-on-plug assemblies, a slight twisting motion will break the seal and ease removal.





Remove the 3 bolts and the 3 LH coil-on-plug assemblies.





73. Remove the 4 bolts, 10 stud bolts and the LH valve cover.
^ Discard the gaskets.

74. NOTE: When removing the coil-on-plug assemblies, a slight twisting motion will break the seal and ease removal.





Remove the 3 bolts and the 3 RH coil-on-plug assemblies.





75. Remove the bolts, stud bolts and the RH valve cover.
^ Discard the gaskets.





76. Remove the 10 bolts, 5 stud bolts and the oil pan.
^ Discard the gasket.





77. Remove the 2 bolts and the oil pump screen and pickup tube.
^ Remove and discard the O-ring seal.





78. Remove the 8 nuts and the oil pan baffle.