Part 2

Engine Front Cover













WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTICE: 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, may cause engine failure.

NOTICE: Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

51. NOTE: LH shown, RH similar.

Remove the cotter pins and nuts from the tie-rod ends.





52. NOTE: LH shown, RH similar.

Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.





53. NOTE: LH shown, RH similar.

Remove the nuts and separate the stabilizer bar links from the struts.





54. Position the Powertrain Lift under the subframe assembly.





55. NOTE: LH shown, RH similar.

Remove the 4 subframe bracket-to-body bolts.





56. NOTE: LH shown, RH similar.

Remove the 2 subframe nuts and the 2 subframe brackets.





57. NOTE: LH shown, RH similar.

Remove the 2 front subframe nuts.





58. Using the Powertrain Lift, lower the subframe assembly from the vehicle.





Front Wheel Drive (FWD) vehicles

59. Remove the 2 RH catalytic converter bracket bolts.





60. Remove the 2 nuts and remove the RH catalytic converter bracket.





All vehicles

61. NOTE: Position a block of wood under the transaxle.

Install the Powertrain Lift and Universal Adapter Brackets.





62. Remove the transaxle support insulator through bolt.





63. Remove the transaxle support insulator bracket bolt and the 2 nuts.





64. Remove the 4 engine mount nuts.
- Remove the 2 engine mount spacers.





65. Remove the nut, 2 bolts and the engine mount.





66. Lower the engine and transaxle assembly from the vehicle.

67. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.





68. If equipped, detach the block heater wiring harness retainers from the PSP hose and the power steering reservoir hose.





69. Disconnect the PCV hose from the PCV valve.





70. Disconnect the Throttle Body (TB) electrical connector.





71. Detach the wiring harness retainers from the upper intake manifold.





72. Remove the upper intake manifold support bracket bolt.





73. 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 6 bolts and the upper intake manifold.

- Discard the gaskets.





74. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.





75. Disconnect the PSP switch electrical connector.





76. Disconnect the RH VCT solenoid electrical connector.





77. Disconnect the 3 RH coil-on-plug electrical connectors.





78. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.

79. Disconnect the LH VCT solenoid electrical connector.





80. Disconnect the 3 LH coil-on-plug electrical connectors.





81. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.

82. NOTE: LH shown, RH similar.

Remove the 6 bolts and the 6 coil-on-plugs.





83. Detach the PSP hose retainer from the engine lifting eye.





84. Remove the PSP hose bracket nut and position the PSP hose aside.





85. Remove the 2 nuts and the wiring harness retaining bracket.





Early build vehicles

86. Loosen the 11 stud bolts and remove the LH valve cover.
- Discard the gasket.





87. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
- Discard the gasket.





Late build vehicles

88. Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.





89. Loosen the 9 stud bolts and remove the RH valve cover.
- Discard the gasket.





All vehicles

90. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





91. Remove the 3 bolts and position the power steering pump aside.





92. Remove the 3 bolts and the accessory drive belt tensioner.





93. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.





94. Using the 3 Jaw Puller, remove the crankshaft pulley.





95. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





96. Remove the 2 bolts and the engine mount bracket.





97. NOTE: Only use hand tools to remove the studs.

Remove the 2 engine mount studs.





98. Remove the 3 bolts and the engine mount bracket.





99. Remove the 22 engine front cover bolts.





100. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence.

1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.

2. Remove the engine front cover.





101. NOTICE: Only use a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.

- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

102. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Do not use wire brushes, power abrasive discs or 3M Roloc(R) Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.
Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block in the following sequence.

1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.