Front Cover Removal
1. Install the memory saver, then disconnect the battery negative cable.2. Raise and support vehicle.
3. Completely drain the radiator of coolant. Do not drain engine oil at this time.
4. Lower the vehicle.
5. Remove the drive belt.
6. Disconnect the clean air tube from the throttle body.
7. Remove the throttle return spring from the throttle body and the accelerator bracket.
8. Disconnect the accelerator and the speed control cables from the throttle body.
9. Position the accelerator bracket away from the upper intake manifold.
10. On vehicles without secondary air injection, proceed as follows:
^ Remove the ignition wire routing clip from the support bracket on the front of the upper intake manifold.
^ Remove the manifold support bracket from the front of the upper intake manifold.
11. On vehicles equipped with secondary air injection, proceed as follows:
^ Disconnect the exhaust tube from the air injection diverter valve. See Figure 14.
^ Disconnect the electrical and the vacuum connections from the air injection diverter valve solenoid. See Figure 14.
^ Remove the air injection diverter valve retainers, then position the valve/supply hose away from the work area. See Figure 14.
^ Remove the ignition wire routing clip from the air injection diverter valve bracket.
^ Remove the air injection diverter valve bracket from the engine. See Figure 14.
12. Disconnect the four (4) vacuum lines from the top of the upper intake manifold, next to the idle air control motor.
13. On vehicles without secondary air injection, disconnect the vacuum lines from the EGR valve and the EVR solenoid, then remove the vacuum harness from the vehicle.
14. On vehicles equipped with secondary air injection, disconnect the vacuum lines from the EGR valve and the EVR solenoid, then position the vacuum harness away from the upper intake manifold.
15. Disconnect the following electrical connectors:
^ Idle air control solenoid
^ Throttle position sensor
^ EVR solenoid
^ EGR transducer
16. Remove the EVR/EGR transducer bracket retaining nuts, then lift up the bracket.
17. Mark and disconnect the EGR transducer vacuum lines.
18. Remove the EVR/EGR transducer bracket assembly.
19. Disconnect the EGR tube from the EGR valve.
20. Remove the PCV valve from the valve cover. Leave the valve attached to the line.
21. Remove the upper intake manifold and gasket. Use care when removing the gasket as it will be reused.
22. Remove the PCV line from the clean air tube to the driver-side valve cover.
23. Disconnect the coolant hose from the left coolant tower. See Figure 15.
24. Disconnect all ignition wires from the coil pack.
25. Disconnect the coil pack and the radio suppressor electrical connectors.
26. Remove the coil pack bracket retainers, then remove the coil pack and the bracket as an assembly.
27. Disconnect the crankshaft position sensor and the camshaft position sensor electrical connectors. Route the wiring harness branch away from the engine front cover.
28. Disconnect the engine coolant temperature sensor electrical connector, located on the left coolant tower.
29. Detach the wiring harness pushpin from the water pump.
30. Disconnect the oil pressure sender electrical connector.
31. Disconnect connector C131, near the oil pressure sender. Route the wiring harness branch away from the engine front cover.
32. Disconnect the coolant hose from the center coolant tower. See Figure 16.
33. Disconnect the coolant hose from the bulkhead side of the coolant tube. See Figure 16.
34. Disconnect the coolant tube from the top of the water pump, then remove the coolant tube assembly from the vehicle. See Figure 16.
35. Disconnect the upper radiator hose from the thermostat housing.
36. Remove the sight shield from the upper radiator support.
37. Remove the coolant recovery bottle upper retaining bracket from the radiator support.
38. Disconnect the coolant overflow hose from the radiator.
39. Remove the coolant recovery bottle.
40. Disconnect the lower radiator hose from the water pump. Position the hose away from the engine front cover.
41. Using Power Steering Pump Pulley Remover (T69L-10300-B), remove the power steering pump pulley.
42. Remove the power steering pump bracket. See Figure 17.
43. Disconnect and remove the camshaft position sensor.
44. Remove the camshaft synchronizer assembly.
45. Remove the water pump pulley, then the water pump.
46. Remove the crankshaft pulley.
47. Using Crankshaft Damper Remover (T58P-6316-D) and Vibration Damper Remover Adapter (T82L-6316-B), remove the crankshaft damper.
CAUTION
Do not damage the front cover or the crankshaft as possible engine oil leakage may occur.
48. Remove the crankshaft front seal from the engine front cover.
49. Install double nuts on the water pump studs, then remove the studs.
50. Remove the oil filter and discard. Do not drain the engine oil at this time. It will be done during the Front Cover Installation procedure.
51. Remove the remaining front cover retainers.
CAUTION
Carefully cut the RTV sealant at the bottom of the front cover with a utility knife and pry carefully on the sides of the cover to avoid cracking the cover.
52. Remove the front cover and the oil filter adapter as an assembly.
53. Prevent debris from entering the block, front cover, oil pan, and oil and coolant passages by taping, plugging, or sealing the passages prior to removing old gasket material. Immediately put shop towels in the front of the oil pan once the front cover is removed and plug the two oil passages in the block. See Figure 18. The passages can be plugged with plastic plugs such as power steering hose plugs or tape. These same two passages must be plugged in the front cover before attempting to remove the old gasket. If debris does enter these passages, it will cause engine damage. The area around these passages should be hand scraped to avoid any possibility of contamination. It is important to prevent contamination from occurring. Debris cannot be cleaned out without engine and front cover disassembly.
NOTE:
Leave rags and plugs in place when cleaning gasket particles off the front of the block. Remember to carefully remove the plugs and rags from the passages and oil pan before installing the new gasket. Use care when removing so that contamination does not enter the engine.
54. Remove the camshaft position (CMP) sensor drive gear.
55. Reinstall the crankshaft damper bolt.
56. Rotate the crankshaft until the timing marks and the keyways are aligned. See Figure 19. This will position cylinder number 1 at TDC of the compression stroke, which is also required for camshaft synchronizer assembly installation.
57. Release tension on the timing chain as follows:
^ Using pliers, compress the timing chain tensioner. See Figure 20.
^ Insent a pick through the tensioner housing and into the tensioner. See Figure 20.
NOTE:
The timing chain and sprockets are being removed to keep debris from collecting on these parts, and to allow more room for cleaning the block front cover mating surface.
58. Remove the camshaft sprocket, crankshaft sprocket and the timing chain as an assembly.
59. Plug the balance shaft hole with a clean shop towel on engines that do not have a balance shaft.
60. Remove the timing chain tensioner.