Steps 1 - 36

Part 1 Of 2:

Part 2 Of 2:

Special Tool(s)

1. 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.

Remove the engine.





2. Remove the bolts and the flexplate or the flywheel.





3. Remove the separator plate.





4. Using the special tools, remove the crankshaft rear oil slinger.





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





6. Remove the rear seal retainer plate.





7. Mount the engine on a suitable engine stand.





8. NOTE: RH shown, LH similar.

Remove the RH and LH lifting eyes.





9. Remove the breather tube.





10. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) electrical connector.





11. Disconnect the hoses from the differential pressure feedback EGR transducer.





12. Remove the EGR vacuum regulator solenoid.
1. Remove the vacuum hoses.
2. Remove the electrical connector.
3. Remove the bolts.





13. Disconnect the EGR tube from the EGR valve.





14. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body.





15. Remove the PCV valve and hose as an assembly.





16. Remove the engine wiring harness.





17. Disconnect the vacuum line from the fuel pressure sensor.





18. Remove the throttle body bolts.





19. NOTE: The gasket is reusable if not damaged.

Remove the throttle body and adapter as an assembly.
^ Inspect and clean the sealing surfaces.





20. Remove the ignition coils.





21. Remove the radio interference capacitors.





22. Rotate the belt tensioner and remove the accessory drive belt.





23. Remove the power steering reservoir bracket as an assembly.
1. Disconnect the supply line from the pump.
2. Remove the three bolts and reservoir and bracket.





24. Remove the upper generator support bracket.





25. Remove the bolts and the generator.





26. Remove the coolant outlet adapter.





27. Remove the thermostat and O-ring.





28. Remove the bolts in the sequence shown, and remove the intake manifold.





29. Remove the intake manifold gaskets.

30. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the sealing surfaces.





31. Remove the coolant bypass tube.
1. Remove the nut.
2. Remove the coolant bypass tube.





32. NOTE: RH shown, LH similar.

Remove the RH and the LH engine mount.





33. NOTE: LH shown, RH similar.

Using a suitable container, drain coolant from the engine block.
^ Install the drain plugs when finished.





34. Remove the four bolts and the power steering pump.





35. Remove the compressor.
1. Remove the bolts.
2. Remove the compressor.





36. Remove the oil filter adapter.
1. Remove the oil bypass filter.
2. Remove the bolts.
3. Remove the oil filter adapter.
4. Clean and inspect the sealing surfaces.