Part 1
Engine
WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.
Special Tool(s)
Material(s)
Exploded View
Intake Manifold and Valve Train Exploded View
Rear Engine Components Exploded View
Timing Drive and Lower Engine Components Exploded View
Disassembly
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
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, can cause engine failure.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
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.
NOTE: Early build engines have a 6-rib crankshaft pulley, late build engines have a 4-rib crankshaft pulley.
1. WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
NOTE: Loosen the 6 clutch pressure plate-to-flywheel bolts evenly, by 2 turns at a time.
If equipped with a manual transmission, remove the 6 clutch pressure plate-to-flywheel bolts, the clutch disc and the pressure plate.
- Discard the pressure plate bolts.
2. If equipped with a manual transmission, install 303-103 (T74P-6375-A) and remove the 6 bolts and the flywheel.
- Discard the bolts.
3. If equipped with a automatic transmission, install 303-103 (T74P-6375-A) and remove the 6 bolts and the flexplate.
- Discard the bolts.
4. Mount the engine on a suitable engine stand.
5. Remove the crankcase vent tube. REFER to Quick Connect Coupling - Type 2 .
6. Disconnect the A/C (Air Conditioning) compressor, CKP (Crankshaft Position) sensor electrical connectors and 2 wiring harness retainers.
7. Disconnect the VCT (Variable Camshaft Timing) oil control solenoids, coil-on-plug assemblies, CMP (Camshaft Position) sensor electrical connectors and wiring harness retainers from valve cover stud bolts.
8. Disconnect the ECT (Engine Coolant Temperature) sensor electrical connector and detach the CMS (Catalyst Monitor Sensor) electrical connector retainer and the 2 wiring harness retainers.
9. Disconnect the EVAP (Evaporative Emission) canister purge valve and fuel injection pump electrical connectors.
10. Remove the bolt and ground wire from the LH (Left Hand) side of the cylinder head.
11. Disconnect and detach the electrical connector and the wiring harness pin-type retainer from the RH (Right Hand) upper side of the intake manifold.
12. Disconnect the generator electrical connector and remove the generator B+ terminal cover.
- Detach the wiring harness retainer from the RH (Right Hand) side of intake manifold.
13. Remove the nut and position the generator B+ harness aside.
14. Detach and disconnect the 2 KS (Knock Sensor) electrical connectors.
15. Disconnect the EOP (Engine Oil Pressure) sensor electrical connector.
16. Detach and disconnect the starter motor harness electrical connector.
17. Disconnect the TB (Throttle Body) electrical connector and the wiring harness retainer.
- Detach the wiring harness retainer from the LH (Left Hand) side of the intake manifold and remove the engine wiring harness.
18. Position 303-1419 between the crankshaft pulley and A/C (Air Conditioning) compressor belt as shown and rotate the crankshaft clockwise.
19. Rotate the crankshaft until 303-1419 is at approximately the 5 o'clock position as shown.
20. Fold 303-1419 around the inside of the A/C (Air Conditioning) compressor belt as shown.
21. In one quick motion, firmly pull the 303-1419 and remove the A/C (Air Conditioning) compressor belt.
22. Loosen the 3 coolant pump pulley bolts.
23. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
24. Remove the 2 bolts and the accessory drive belt tensioner.
25. Remove the 3 bolts and the coolant pump pulley.
26. Remove the 3 bolts and the coolant pump.
- Discard the O-ring seal.
27. Remove the 4 bolts and the A/C (Air Conditioning) compressor and shield.
28. Disconnect and remove the coolant return hose.
29. Remove the nut, 2 bolts and the generator.
- Remove the generator stud.
30. Remove the 3 bolts and the thermostat housing.
- Discard the thermostat housing gasket.
31. Disconnect the fuel vapor tube quick connect coupling from the intake manifold. REFER to Quick Connect Coupling - Type 1 .
- Detach and remove the EVAP (Evaporative Emission) canister purge valve.
32. 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 intake manifold bolts.
- Position back the intake manifold to allow access to disconnect the crankcase ventilation oil separator tube from the intake manifold.
- Remove the intake manifold.
33. Disconnect the coolant bypass hose and detach from the retainer clip and remove.
34. Disconnect the 4 fuel injector, FRP (Fuel Rail Pressure) sensor electrical connectors and detach the 2 fuel rail wiring harness retainers and remove the fuel rail noise insulator.
35. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
Remove the fuel injection pump noise insulator shield.
36. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.
Remove the high pressure fuel tube.
1. Remove the high pressure fuel tube bracket bolts.
2. Loosen the high pressure fuel tube-to-fuel rail flare nut.
3. Loosen the high pressure fuel tube-to-fuel injection pump flare nut.
4. Remove and discard the high pressure fuel tube.
37. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.
Remove the 4 bolts and remove the fuel rail.
38. Using the 307-005 (T59L-100-B) and the 310-206 , remove any of the fuel injectors that remained in the head.
39. Remove and discard the fuel injector clips.
40. Remove and discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.
41. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use a brush to clean the tip of the fuel injector.
Using the 310-205 , clean the 4 fuel injector bores in the cylinder head.
42. Remove the 8 bolts and the crankcase vent separator.
- Remove and discard the gasket.
43. Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
44. NOTICE: The RH (Right Hand) KS (Knock Sensor) must be installed in the 6 o'clock position and the LH (Left Hand) KS (Knock Sensor) must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine.
NOTE: Mark the location of the RH (Right Hand) and LH (Left Hand) KS (Knock Sensor).
Remove the 2 bolts and the KS (Knock Sensor).
45. Remove the 2 bolts and the catalytic converter support bracket.
46. Remove the 3 bolts and the intermediate shaft bearing bracket.
47. Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time, remove the 2 bolts and fuel injection pump.
- Discard the bolts.
48. Remove and discard the fuel injection pump O-ring seal.
49. Remove the fuel injection pump tappet.
