Steps 1-60

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 flexplate or flywheel, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

Vehicles with automatic transmission

1. Remove the 6 bolts and the flexplate.





Vehicles with manual transmission

2. Remove the 6 flywheel bolts.

3. NOTICE: 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.





All vehicles

4. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove the crankshaft rear oil slinger.
- Discard the crankshaft rear oil slinger.





5. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove the crankshaft rear seal.
- Discard the crankshaft rear seal.





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

Clean and inspect the sealing surfaces.





7. Mount the engine on a suitable work stand.

8. Remove the Engine Lifting Bracket.





9. NOTE: RH shown, LH similar.

Disconnect the RH and LH Camshaft Position (CMP) sensor electrical connectors.





10. NOTE: RH shown, LH similar.

Disconnect the RH and LH Variable Camshaft Timing (VCT) solenoid electrical connectors.





11. Detach the engine wiring harness pin-type retainers.





12. Remove the nut and the RH radio ignition interference capacitor.





13. NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.

NOTE: LH shown, RH similar.

Remove the PCV tubes from the LH and RH valve covers.

- Disconnect the quick connect fittings.
- Push the connector toward the valve cover to release pressure.

- Push the release tab clockwise.

- Disconnect the quick connect fitting.





14. NOTE: RH shown, LH similar.

Disconnect the 4 RH and 4 LH ignition coil electrical connectors.





15. Disconnect the 3 engine wiring harness retainers from the RH valve cover studs.





16. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.





17. Detach the engine wiring harness pin-type retainers.





18. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.





19. Detach the CHT sensor jumper harness electrical connector pin-type retainer.





20. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.





21. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
- Detach the engine wiring harness retainer from the stud bolt.





22. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.





23. Remove the engine wiring harness from the engine.

24. Remove the nut and ground strap from the stud bolt.





25. NOTE: LH shown, RH similar.

Remove the 8 bolts and the 8 ignition coils.





26. Remove the bolt and the oil level indicator tube.





27. 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.

NOTE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

NOTE: The bolts are part of the valve cover and should not be removed.

NOTE: LH shown, RH similar.

Loosen the 19 bolts and remove the valve covers.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





28. Remove and discard the oil filter.

29. Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.





30. Remove the 4 bolts and the LH motor mount bracket.





31. Remove the 8 nuts and the LH exhaust manifold.
- Discard the nuts and gasket.





32. Clean and inspect the LH exhaust manifold.

33. Remove and discard the 8 LH exhaust manifold studs.

34. Remove the 2 bolts, 2 stud bolts and the RH motor mount bracket.





35. Remove the 8 nuts and the RH exhaust manifold.
- Discard the nuts and gasket.





36. Clean and inspect the RH exhaust manifold.

37. Remove and discard the 8 RH exhaust manifold studs.

38. Remove the 2 bolts and the KS.





39. Remove the bolt and the RH CMP sensor.





40. Remove the bolt and the LH CMP sensor.





41. Remove the bolt and the CKP sensor.





42. Remove the 7 bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.





43. Remove the 3 bolts and the accessory drive belt tensioner.





44. Remove the 4 coolant pump housing bolts.





45. Remove the coolant pump housing from the cylinder block.
- Discard the O-ring seal.





46. Remove the stud bolt and the coolant tube assembly.
- Discard the O-ring seal.





47. Remove and discard the crankshaft pulley bolt. Using the 3-Jaw Puller, remove the crankshaft pulley.





48. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.





49. Remove the bolts, oil pan and oil pan gasket.
- Discard the oil pan gasket.

- 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.

Clean and inspect the sealing surfaces.





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

Remove the engine front cover fasteners.





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





52. Remove the crankshaft sensor ring from the crankshaft.





53. Position the crankshaft keyway at the 12 o'clock position.





54. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to the 12 o'clock position.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.





55. 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.

Remove only the 3 roller followers shown in the illustration from the RH cylinder head.





56. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.





57. 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.

Remove only the 3 roller followers shown in the illustration from the LH cylinder head.





58. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, remove the 3 roller followers designated in the previous step from the LH cylinder head.





59. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.





60. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.