Part 1 of 2

Engine





Special Tool(s)





1. Separate the engine control sensor wiring connectors from the upper intake manifold.





2. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.





3. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid and the differential pressure feedback EGR system electrical connectors.





4. Remove the positive crankcase ventilation (PCV) tube.





5. Disconnect the vacuum hose from the fuel pressure regulator.





6. Disconnect and remove the engine control wire harness.





7. Remove the bolts and upper intake manifold.





8. Disconnect the crankshaft and camshaft position sensor electrical connectors.





9. Disconnect the radio ignition interference capacitor electrical connectors.





10. Disconnect the engine coolant temperature (ECT) sensor and the oil pressure switch.





11. Disconnect the remaining electrical connectors and harness retainers and remove the harness.





12. CAUTION: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.

Remove the bolts and the six coil-on-plugs.





13. Remove the dower intake manifold and discard the gaskets.





14. Remove the nut and the radio interference capacitors.





15. Remove the RH valve cover.
- Remove and discard the gasket.





16. Remove the engine lift bracket.





17. Remove the nuts, the LH exhaust manifold and the gasket. Discard the gasket.





18. Remove the nuts, the RH exhaust manifold and the gasket. Discard the gasket.





19. Remove the knock sensor.





20. Remove the LH valve cover.
- Remove and discard the gasket.





21. Disconnect the hoses.





22. Remove the water pump assembly.





23. Disconnect the coolant hoses at the oil cooler.





24. Remove the bolt.





25. Using the special tool, remove the crankshaft damper.





26. Remove the power steering pump pulley.





27. Remove and discard the oil filter.





28. Remove the power steering pump.





29. Remove the generator support bracket.





30. Remove the oil cooler.





31. Remove the oil pressure sender and the block heater.





32. Remove the bolts and studs and the oil pan.
- Discard the gasket.





33. Remove the bolts, nut and the oil pump screen and pickup tube.





34. Remove the nuts and the oil pan baffle.





35. Remove the stud bolt and the oil level indicator and tube.





36. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Remove the bolts, studs and the front cover
- Discard the gasket.





37. Remove and discard the crankshaft front seal from the front cover.





38. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-2S-34Y-30M (Color Blue).

Remove the ignition pulse wheel.





39. Install the damper bolt.