Part 1

Engine














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

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.

NOTE: The flywheel, crankshaft rear oil slinger, crankshaft rear seal and crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

1. Remove the 8 flywheel bolts.

2. NOTICE: The flywheel is a press fit on the crankshaft pilot. Do not use screwdrivers or prybars to remove the flywheel or damage to the flywheel or engine may occur.

Remove the flywheel.
- Install 2 of the removed flywheel bolts in the 2 holes shown on the flywheel flange.

- Tighten the 2 bolts evenly to push the flywheel off the crankshaft pilot.






3. Remove the engine/transmission spacer plate.

4. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove the crankshaft rear oil slinger.





5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove the crankshaft rear seal.





6. Remove the 8 bolts and the rear seal retainer plate.
- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the mating surfaces.






7. Mount the engine on a suitable work stand.





8. Remove the coolant tube bracket nut.





9. Disconnect the 2 upper radiator hoses from the intake manifold.





10. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.





11. Remove the 2 nuts and the thermostat housing assembly.





12. Loosen the 4 coolant pump pulley bolts.





13. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





14. Remove the bolt, Supercharger (SC) drive belt tensioner and the SC (Supercharger) drive belt.





15. Detach the 2 wiring harness pin-type retainers from the oil pan.





16. Remove the nut and the ground wire from the RH engine support insulator bracket stud bolt.





17. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





18. Detach the wiring harness retainer and remove the 2 nuts and the wire harness brackets from the oil pan stud bolts.





19. Remove the nut and disconnect the B+ wire from the generator.





20. Disconnect the generator electrical connector.





21. Remove the 3 bolts and the generator.





22. Remove the bolt and the accessory drive belt tensioner.





23. Remove the 3 bolts and the accessory drive belt idler pulley.





24. Remove the stud bolt and the accessory drive belt idler pulley (smooth).





25. Remove the bolt and the accessory drive belt idler pulley (grooved).





26. Remove the 4 bolts and the coolant pump pulley.





27. Remove the 3 bolts and the 3 SC (Supercharger) drive belt idler pulleys.





28. Disconnect the 2 EGR tube fittings.
- Remove the EGR tube.






29. Disconnect and remove the crankcase ventilation tube.





30. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.





31. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.





32. Remove the 4 bolts and the Throttle Body (TB) and spacer assembly.
- Discard the gasket.






33. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.





34. Detach the 2 wiring harness pin-type retainers (1 shown) from the coolant tube assembly bracket.





35. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.





36. Disconnect the bubbler tube from the SC (Supercharger).





37. Disconnect the Knock Sensor (KS) electrical connector.





38. Remove the 2 bolts and the wiring harness retaining bracket.





39. Detach the 2 wiring harness pin-type retainers.





40. Disconnect the PCV valve electrical connector.





41. Disconnect the 4 RH fuel injector electrical connectors.





42. Disconnect the fuel rail pressure and temperature sensor electrical connector.





43. Remove the nut and position aside the RH radio interference capacitor.





44. Disconnect the EGR valve electrical connector.





45. Detach the 2 wiring harness retainers from the RH coil-on-plug cover stud bolts.





46. Detach the wiring harness retainers from the RH valve cover stud bolts.





47. Remove the 2 stud bolts and the RH coil-on-plug cover.





48. Disconnect the 4 RH coil-on-plug electrical connectors.
- Remove the 4 RH coil-on-plugs.






49. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.