Part 1

Engine








Special Tool(s)





Material

Disassembly

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.





1. Remove the bolts and the flexplate.





2. Remove the engine/transmission spacer Plate.





3. Using the special tools, remove the rear oil seal slinger.





4. Using the special tools, remove the rear main seal.





5. Remove the eight bolts and the crankcase rear oil seal retainer.





6. Mount the engine on a suitable engine stand.





7. NOTE: RH shown; LH similar.

Remove the LH and the RH engine mount.





8. NOTE: LH shown; RH similar.

Remove the drain plugs from the engine block.
Allow the coolant to completely drain.
^ Install the drain plugs when finished.





9. Remove the bolt and the battery cables from the engine.





10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.





11. Disconnect the eight ignition coil electrical connectors.





12. Disconnect the eight fuel injector electrical connectors.





13. Remove the bolts and the EGR tube heat shield.





14. Disconnect and remove the crankcase ventilation tube.





15. Remove the generator mounting bracket.
^ Remove the bolts.
^ Remove the bracket.





16. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.





17. Disconnect the generator electrical connector.





18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.





19. Remove the generator wiring harness anchor from the LH front stud.





20. Disconnect the ground wire from the RH rear stud.





21. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





22. Disconnect the camshaft position (CMP) sensor electrical connector.





23. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.





24. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.





25. Disconnect the vacuum hoses and the electrical connector.





26. Disconnect the fuel charging wiring from the crash bracket and remove the harness from the engine assembly.





27. Disconnect the EGR tube nut from the EGR valve.





28. Remove the generator.
1. Remove the bolts.
2. Remove the generator.





29. Remove the four bolts.





30. Remove the bolt and the stud.
^ Remove the crash bracket.





31. Remove the eight bolts and the eight ignition coils.





32. Remove the bolts and the coolant outlet adapter.





33. Remove the thermostat.





34. Remove the bolts and the intake manifold.





35. Remove the intake manifold gaskets.





36. CAUTION: 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.

Clean the sealing surfaces.





37. Remove the coolant bypass tube.
1. Remove the retaining nut.
2. Remove the ground strap.
3. Remove the coolant bypass tube.





38. Remove the knock sensor.





39. Remove the studs and bolts and remove the valve cover.
^ Clean the mating surface and, if necessary, install new gaskets.





40. Remove the studs and bolts, and remove the right valve cover.
^ Clean the mating surface and, if necessary, install new gaskets.





41. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

Remove the spark plugs.





42. Position the lobe of the camshaft up.





43. Install the special tool between the valve spring coils to prevent valve stem seal damage.





44. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.

Use the special tool to compress the valve springs and remove the camshaft roller followers.





45. Remove the bolt and the belt idler pulley.





46. Remove the bolts and the coolant pump pulley.





47. Remove the bolts and the coolant pump.





48. Remove the crankshaft pulley bolt.





49. Remove the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.





50. Use the special tool to remove the crankshaft front seal.





51. Remove the bolts, and the oil pan and gasket.





52. Remove the bolts, and the oil pump screen cover and tube.





53. Remove the oil pump screen cover and tube spacer.





54. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Remove the fasteners in the sequence shown.





55. Remove the engine front cover from the cylinder block.





56. Remove the crankshaft sensor ring from the crankshaft.





57. Position the crankshaft with the keyway at the 12 o'clock position.





58. Remove the timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.





59. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Remove the LH and RH timing chains and the crankshaft sprocket.
Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Repeat for the LH timing chain and crankshaft sprocket.





60. Remove both timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.





61. Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket.