Service Procedure - Part 1

SI Documents

Before starting this new service procedure outlined in this bulletin, refer to the following SI documents and review. Print the SI documents with an asterisk (*) next to the document . The asterisk indicates additional service information shown in this bulletin.

Fuel Pressure Relief

Air Cleaner Resonator and Outlet Duct Replacement

Battery Replacement (LK5 or L52 Engine Only)

Evaporative Emission Hoses/Pipes Replacement - Engine

Lifting and Jacking the Vehicle

Draining and Filling Cooling System (Static Fill)

Draining and Filling Cooling System (Vac-N-Fill) *

Wheelhouse Panel Replacement (Front)

Cylinder Head Replacement *

Cylinder Head Disassemble *

Engine Coolant Temperature Sensor Replacement *

Valve Rocker Arm and Valve Lash Adjusters

Intake Camshaft Position Sensor Installation *

Exhaust Camshaft Position Sensor Installation *

Water Outlet Installation *

Camshaft Position Actuator Solenoid Valve Installation *

Cylinder Head Cleaning and Inspection

Camshafts Cleaning and Inspection

Camshaft Installation *

Camshaft Cover Cleaning and Inspection

Exhaust Manifold Replacement *

Intake Manifold Replacement *

Tire and Wheel Removal and Installation *

Oil Pan Skid Plate Replacement (LK5 or L52 Engine Only) *

Engine Shield Replacement (LK5 or L52 Engine Only) *

Oil Level Indicator and Tube Replacement Removal Procedure *

Engine Lift Bracket Replacement *

Power Steering Pump Replacement (LL8 Engine Only)

Drive Belt Replacement *

Generator Replacement *

Capacities - Approximate Fluid *

Engine Cylinder Head Removal

Install protective covering to the front of the vehicle. This is to protect the grille from damage.

Install fender covers.

Bleed the fuel pressure. Refer to Fuel Pressure Relief in SI.

Remove the air cleaner resonator, the outlet duct and the air cleaner assembly.

Refer to Air Cleaner Resonator and Outlet Duct Replacement Removal Procedure in SI.

Refer to Air Cleaner Assembly Replacement in SI. Disconnect the negative battery cable (LL8 Engine Only).

Remove the battery from the vehicle. Refer to Battery Replacement in SI (LK5 or L52 Engine Only).

Disconnect the Fuel/EVAP lines from the intake manifold and move aside (includes fuel line removal from fuel rail). Refer to Evaporative Emission Hoses/Pipes Replacement - Engine in SI.

Remove the bolt holding the oil indicator (dipstick) tube to the intake manifold and move the oil dipstick aside (Do not remove).

Drain the engine coolant. Refer to Draining and Filling Cooling System (Static Fill) in SI.

Lift the Vehicle. Refer to Lifting and Jacking the Vehicle in SI.

Remove the bolts holding the engine shield (LK5 or L52 Engine Only).

Remove the engine shield from the vehicle (LK5 or L52 Engine Only.

Remove the bolts holding the oil pan skid plate (LK5 or L52 Engine Only).

Remove the oil pan skid plate from the vehicle (LK5 or L52 Engine Only).

Remove the drive belt.

Drain the engine oil.

Remove left front tire and wheel.

Remove the left front wheelhouse panel. Refer to Wheelhouse Panel Replacement (Front) in SI.

Remove the fir tree wiring harness connectors from the engine wring harness bracket from the left front wheelhouse opening.

From the left front wheelhouse, remove the engine wiring harness bracket from the engine and set aside. It may be necessary to loosen the fasteners on the frame rail (LL8 Only).

Remove the intake manifold bolts from the wheelhouse access (bolts stay with intake manifold). On two-wheel drive vehicles, the intake manifold bolts are removed from the top of the engine, not through the left front wheelhouse panel.

Lower the vehicle.

Remove the PCV pipes from the cam cover and remove the intake manifold from the vehicle.

Remove the PCM engine harness connectors from the PCM (LL8 Engine Only).

Remove the PCM from the intake manifold bracket (LL8 Engine Only).

Remove the generator output BAT terminal nut.

Remove the generator lead from the generator.

Disconnect the generator electrical connector.

Remove the generator bolts and set the generator aside. The generator does not have to be removed from the vehicle. On a two-wheel drive vehicle, the generator must be removed from the vehicle.

Remove the generator (LL8 Engine Only).

Disconnect the A/C pipe clamp from the engine lift hook bracket.

Remove the engine lift hook bracket bolts and bracket from the vehicle.

Remove the P/S pump bolts and reposition the pump (LL8 Engine Only).

Remove the bolts holding the windshield washer solvent container and coolant recovery reservoir to the right inner fender. Move aside to gain access to the engine wiring harness to PCM (LK5 or L52 Engine Only).

Disconnect the following cross-vehicle engine wiring harness connectors:

PCM

Engine Coolant Temperature Sensor

MAP Sensor

Ignition Coils

Harness clamps at power steering pump

Wiring Harness fastener at right front inner fender

Throttle Body

Camshaft Sensors

Exhaust Camshaft Actuator

Fuel Injectors