Part 2
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.
50. Disconnect the Camshaft Position (CMP) sensor electrical connector.
51. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
52. Disconnect the 4 LH fuel injector electrical connectors.
53. Remove the nut and position aside the LH radio interference capacitor.
54. Detach the wiring harness retainers from the LH valve cover stud bolts.
55. Remove the 2 bolts and the LH coil-on-plug cover.
56. Disconnect the 4 LH coil-on-plug electrical connectors.
- Remove the 4 LH coil-on-plugs.
57. Remove the wiring harness assembly from the engine.
58. Disconnect the intake manifold-to-coolant tube assembly hose.
59. 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 14 bolts and the intake manifold assembly.
- Remove and discard the 2 intake manifold gaskets.
60. Remove the 2 bolts and the KS (Knock Sensor).
61. Remove the stud bolt, 3 bolts and the RH engine support insulator bracket.
62. Remove 8 nuts and the RH exhaust manifold.
- Discard the nuts and gaskets.
63. Clean and inspect the RH exhaust manifold.
64. Remove and discard the 8 RH exhaust manifold studs.
65. Remove the 4 bolts and the LH engine support insulator bracket.
66. Remove 8 nuts and the LH exhaust manifold.
- Discard the nuts and gaskets.
67. Clean and inspect the LH exhaust manifold.
68. Remove and discard the 8 LH exhaust manifold studs.
69. Remove the 3 coolant tube assembly bolts.
70. Remove the oil level indicator, the bolt and the oil level indicator tube.
- Remove and discard the oil level indicator tube O-ring seal.
71. Remove the 3 bolts and the coolant tube assembly.
72. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the 6 bolts and the oil cooler.
- Discard the oil cooler and the gaskets.
73. Remove the 8 bolts and the oil filter adapter.
- Discard the oil filter adapter gasket.
74. 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.
Remove the 13 bolts, 3 stud bolts and the oil pan.
- Remove and discard the oil pan gasket.
- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.
75. Remove the 3 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.
76. Remove and discard the oil pan baffle and gasket.
77. Remove the oil pump screen and pickup tube spacer.
78. 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.
Remove the bolts, stud bolts and RH valve cover.
- Remove and discard the gaskets.
- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.
79. 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.
Remove the bolts, stud bolts and LH valve cover.
- Remove and discard the gaskets.
- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.
80. Remove the bolt and the Crankshaft Position (CKP) sensor.
81. Remove the bolt and the CMP (Camshaft Position) sensor.
82. Remove the 4 bolts and the coolant pump.
83. Using the Strap Wrench, remove the crankshaft pulley bolt and the washer.
- Discard the bolt.
84. Using the 3 Jaw Puller, remove the crankshaft pulley.
85. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
86. 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.
Remove the 16 bolts and the engine front cover.
- Remove and discard the engine front cover gaskets.
- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.
87. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
NOTE: RH shown, LH similar.
Remove the 8 spark plugs.
88. NOTICE: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
Using the Valve Spring Compressor, compress the valve spring and remove the roller follower.
89. Repeat the previous step to remove each of the roller followers. Inspect the roller followers.