Steps 1 - 39
EnginePart 1 Of 2:
Part 2 Of 2:
Special Tool(s)
Disassembly
1. Remove the bolts and the flywheel.
2. Using the special tool, remove the rear oil slinger.
3. Using the special tool, remove the rear main seal.
4. Remove the bolts and the rear seal retainer plate.
5. Mount the engine on a workstand.
6. Remove the special tools.
7. Remove the drain plug and drain the engine coolant.
8. Disconnect the electrical connectors from the fuel pulse damper, Exhaust Gas Recirculation (EGR) vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
9. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
10. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator.
11. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
12. Disconnect the vacuum hose from the EGR valve.
13. Disconnect the vacuum hoses at the back of the supercharger and remove the vacuum harness.
14. Remove the vacuum accessory bracket mounting nut.
15. Remove the mounting bolts and the vacuum accessory bracket.
16. Remove the Positive Crankcase Ventilation (PCV) valve.
17. Disconnect and remove the PCV hose.
18. Disconnect the Barometric Pressure (BARO) sensor electrical connector.
19. Disconnect the EGR tube from the exhaust manifold.
20. NOTE: Discard the EGR valve gasket.
Remove the EGR valve and tube as an assembly.
21. Disconnect the electrical connectors and remove the LH ignition coils.
22. Disconnect the Camshaft Position (CMP) sensor electrical connector.
23. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector and unclip the harness from the stud.
24. NOTE: LH is shown, RH is similar.
Disconnect the two radio ignition interference capacitor electrical connectors.
25. Remove the fuel charging wiring harness bracket bolt.
26. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
27. Disconnect the A/C compressor electrical connector.
28. Unclip the harness from the bracket.
29. Remove the harness support bracket.
30. Disconnect the electrical connectors and remove the RH ignition coils.
31. Disconnect the eight fuel injectors.
32. Separate the harness from the fuel supply manifold studs in four places and remove the fuel charging wiring harness.
33. NOTE: The intake manifold gaskets are reusable if undamaged.
Remove the ten bolts and the intake manifold, and the supercharger and fuel supply manifold as an assembly.
34. Remove the bolts and the heater water outlet tube.
35. Remove the bolts and the heater water inlet tube.
36. NOTE: LH is shown, RH is similar.
Remove the coolant bypass studs.
37. NOTE: LH is shown, RH is similar.
Remove the bolts and the coolant bypass tube.
38. Remove the bolts and the heater water inlet tube.
39. 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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: LH is shown, RH is similar.
Remove the fasteners and the LH and RH valve covers.
^ Remove and discard the gasket, clean and inspect the sealing surfaces.