Part 1

Engine











Disassembly (Steps 1-37)

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

CAUTION: 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.

1. Remove the 8 flywheel bolts.

2. CAUTION: 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 special tools, remove the crankshaft rear oil slinger.





5. Using the special tools, remove the crankshaft rear seal.





6. Remove the 8 bolts and the rear seal retainer plate.

^ 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.

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. Disconnect the coolant hose from the thermostat housing.





9. Remove the coolant tube bracket nut.





10. Disconnect the 2 coolant vent hoses from the intake manifold.





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





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





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





14. Disconnect the coolant hose from the charge air cooler (CAC).





15. Loosen the 4 coolant pump pulley bolts.





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





17. Remove the bolt, supercharger (SC) drive belt tensioner and the SC drive belt.





18. Remove the power steering tube bracket nut.





19. Remove the power steering tube bracket bolt.





20. Remove the 2 power steering reservoir bracket bolts.





21. Remove the 3 bolts and the power steering pump and reservoir assembly.





22. Disconnect the generator electrical connector.





23. Detach the 2 wiring harness pin-type retainers from the generator.





24. Remove the stud bolt, 2 bolts and the generator.





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





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





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





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





29. Remove the 3 bolts and the 3 SC drive belt idler pulleys.





30. Disconnect the 2 EGR tube fittings.
^ Remove the EGR tube.





31. Disconnect and remove the crankcase ventilation tube.





32. Disconnect the throttle position (TP) sensor electrical connector.





33. Disconnect the electronic throttle control electrical connector.





34. Remove the 4 bolts and the TB and spacer assembly.





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





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





37. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and pin-type retainer.