Part 1

Engine

Special Tool(s):

Special Tool(s):

General Equipment:

Disassembly (Steps 1-30)

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.

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

CAUTION: If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.





1. Remove the 8 bolts and the flexplate or flywheel.





2. Remove the spacer plate and if equipped, the flexplate-to-crankshaft spacer.
3. Mount the engine on a suitable engine stand.





4. Disconnect the generator and throttle body (TB) electrical connectors.





5. Remove the nut and detach the B+ terminal from the generator.
^ Detach the wiring retainer from the coolant tube bracket.





6. Disconnect the vacuum tube and the fuel rail pressure and temperature sensor electrical connector.





7. Disconnect the exhaust gas recirculation (EGR) system module and throttle position (TP) sensor electrical connectors.





8. Disconnect the EGR tube fitting from the EGR system module.





9. Disconnect the EGR tube fitting from the LH exhaust manifold and remove the tube.





10. Disconnect the 2 (TB) coolant hoses from the coolant tube.





11. Disconnect the positive crankcase ventilation (PCV) tube fittings and remove the tube.





12. Disconnect the knock sensor (KS) electrical connector and detach the wiring retainer.





13. Remove the 8 bolts and the intake manifold.





14. Remove the 2 fuel supply tube bracket bolts.





15. Disconnect the camshaft position (CMP) electrical connector.





16. Disconnect the oil pressure sensor electrical connector and detach the wiring retainer.





17. Remove the bolt and the belt tensioner.





18. Remove the 2 bolts, the nut and the generator and bracket.





19. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the 2 wiring retainers.





20. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





21. Disconnect the PCV valve electrical connector.





22. Disconnect the 3 LH fuel injector electrical connectors and detach the wiring retainer from the valve cover stud bolt.





23. Disconnect the 3 RH fuel injector electrical connectors and detach the wiring retainer from the valve cover stud bolt.





24. Remove the 3 bolts, detach the wiring retainers and remove the main engine wiring harness.





25. Remove the 4 bolts and then remove the fuel rail and injectors.





26. Remove the bolt and the KS.





27. Remove the bolt and then disconnect the coolant bypass hose and the heater hose from the coolant pump.





28. Remove the 3 bolts and then remove the thermostat housing, hoses and coolant tube.





29. Remove the 3 bolts, the 3 stud bolts and the LH valve cover.





30. Remove the 2 bolts, the 4 stud bolts and the RH valve cover.