Engine Disassembly
TOOL REQUIREDJ 36660 Torque Angle Meter
J 24420-B Crankshaft Balancer Remover
J 29113 Crankshaft Balancer Installer
J 5825-A Crankshaft Sprocket Remover
J 24270 Ridge Reamer
J 33049 Camshaft Bearing Remover/Installer
NOTE: Before beginning disassembly procedures, carefully drain fluids as follows:
1. Remove the oil pan plug.
2. Drain the engine oil into a suitable container.
3. Remove the oil filter.
4. Remove the coolant drain plugs.
5. Drain the coolant into a suitable container.
DISASSEMBLY STEPS
1. Engine Flex Plate Removal
a. Remove the exhaust crossover pipe heat shield screws.
b. Remove the exhaust crossover pipe heat shield.
c. Remove the exhaust crossover pipe retaining nuts.
d. Remove the exhaust crossover pipe.
e. Remove the flex plate retaining bolts.
f. Remove the retainer.
g. Remove the flex plate.
2. Upper Intake Manifold Removal
a. Disconnect the vacuum lines from the upper intake manifold.
b. Remove the MAP sensor electrical connector.
c. Remove the MAP sensor screws.
d. Remove the MAP sensor.
e. Remove the generator pencil brace nuts and bolts.
f. Remove the generator pencil braces.
g. Disconnect the spark plug wires from the spark plugs.
h. Remove the electronic ignition control module nuts and bolts.
i. Remove the electronic ignition control module.
j. Remove the EVAP canister purge valve mounting bracket.
k. Remove the EGR tube assembly from the right exhaust manifold.
l. Remove the thermostat bypass pipe nut from the upper intake manifold.
m. Disconnect the coolant hoses from the throttle body.
n. Remove the upper intake manifold studs and bolts.
o. Remove the upper intake manifold.
p. Remove the upper intake manifold gaskets.
3. Lower Intake Manifold Removal
a. Remove the fuel injector rail bolts.
b. Remove the fuel injector rail assembly.
c. Remove the heater inlet pipe assembly.
d. Remove the retaining bolts.
e. Remove the lower intake manifold.
f. Remove the lower intake manifold gaskets.
4. Exhaust Manifold Removal (Left Side)
a. Remove the exhaust manifold heat shield bolts.
b. Remove the exhaust manifold heat shield.
c. Remove the exhaust manifold retaining nuts.
d. Remove the exhaust manifold.
e. Remove the exhaust manifold gasket.
5. Exhaust Manifold Removal (Right Side)
a. Remove the lower exhaust manifold heat shield bolts.
b. Remove the lower exhaust manifold heat shield.
c. Remove the upper exhaust manifold heat shield bolts.
d. Remove the upper exhaust manifold heat shield.
e. Remove the exhaust manifold retaining nuts.
f. Remove the exhaust manifold.
g. Remove the exhaust manifold gasket.
6. Valve Rocker Arm Cover Removal (Left Side)
a. Remove the thermostat bypass hose clamp.
b. Remove the thermostat coolant bypass pipe retaining bolt, nut, and screw.
c. Remove the thermostat coolant bypass pipe.
d. Remove the valve rocker cover bolts.
e. Remove the valve rocker cover.
f. Remove the valve rocker gasket.
7. Valve Rocker Arm Cover Removal (Right Side)
a. Remove the generator bracket bolts.
b. Remove the generator bracket assembly.
c. Remove the valve rocker cover bolts.
d. Remove the valve rocker cover.
e. Remove the valve rocker gasket.
8. Valve Rocker Arm and Push Rod Removal
a. Remove the rocker arm bolts.
CAUTION: Place the valve train parts in a rack in order to ensure that they are installed in the same location from which they were removed. Intake pushrods measure 144.18 mm (5.68 inches). Exhaust pushrods measure 152.51 mm (6.0 inches).
b. Remove the rocker arms.
CAUTION: Use care when removing the pushrods. Ensure that they do not fall down into the lifter valley.
c. Remove the pushrods.
9. Valve Lifter Removal
a. Remove the valve lifter guide bolts.
b. Remove the valve lifter guide.
c. Remove the valve lifters.
10. Crankshaft Balancer Removal
a. Remove the crankshaft balancer retaining bolt and washer.
b. Remove the crankshaft balancer.
11. Oil Pan Removal
a. Remove the oil pan side bolts.
b. Remove the oil pan bolts.
c. Remove the oil pan.
d. Remove the oil pan gasket.
12. Oil Pump Removal
a. Remove the crankshaft oil deflector nuts.
b. Remove the crankshaft oil deflector.
c. Remove the oil pump bolt.
d. Remove the oil pump.
e. Remove the drive rod.
13. [1][2]Engine Front Cover Removal
a. Remove the drive belt tensioner bolt.
b. Remove the drive belt tensioner.
c. Remove the large front cover bolts (2).
d. Remove the small front cover bolts (1).
e. Remove the front cover.
f. Remove the front cover gasket.
14. Timing Chain and Sprockets Removal
a. Remove the camshaft sprocket bolt.
b. Remove the camshaft sprocket.
c. Remove the timing chain.
d. Remove the crankshaft sprocket. Use the Crankshaft Sprocket Remover.
e. Remove the timing chain dampener bolts.
f. Remove the timing chain dampener.
15. Cylinder Head Removal (Left Side)
a. Remove the oil level indicator assembly retaining bolt.
b. Remove the oil level indicator assembly.
c. Remove the cylinder head bolts.
d. Remove the cylinder head assembly.
e. Remove the cylinder head gasket.
16. Cylinder Head Removal (Right Side)
a. Remove the cylinder head bolts.
b. Remove the cylinder head assembly.
c. Remove the cylinder head gasket.
17. Camshaft Removal
a. Remove the oil pump driven gear hold down clamp bolt.
b. Remove the oil pump driven gear hold down clamp.
c. Remove the oil pump driven gear assembly.
CAUTION: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
d. Remove the camshaft thrust plate screws.
e. Remove the camshaft thrust plate.
f. Remove the camshaft. Use the following procedure to remove it:
^ Install a large screwdriver carefully in the camshaft bolt hole.
^ Carefully rotate and pull the camshaft out of the camshaft bearings.
18. Piston, Connecting Rod, and Bearing Removal
a. Mark the piston with the number of the cylinder from which it is being removed.
b. Mark the connecting rod and the rod cap so that they can be assembled correctly.
c. Turn the crankshaft to bottom dead center.
CAUTION: If there is a pronounced ridge at the top of the piston travel, the ridge must be removed with a ridge reamer before the piston and connecting rod assembly are removed. Applying force may break the piston rings or damage the piston.
d. Cover the piston with a shop towel.
e. Remove the cylinder ridge. Use the J 24270 ridge reamer, or equivalent, if necessary.
f. Remove the shop towel and metal shavings from the cylinder.
g. Clean the carbon from the top end of the cylinder.
h. Clean any metal shavings from cylinder bore.
i. Remove the connecting rod nut and cap.
CAUTION: Install thread protector in order to avoid damage to the crankshaft journal.
j. Remove the connecting rod and piston assembly. Push it out with a suitable tool.
19. Crankshaft Rear Oil Seal Removal
^ Remove the crankshaft rear oil seal from the crankshaft.
20. Camshaft Bearing Removal
a. Remove the rear camshaft cover.
CAUTION: The camshaft bearings must not be re-used after they have been removed.
b. Use the following procedure in order to drive out the bearings:
^ Select the expander assembly and driving washer.
^ Assemble Camshaft Bearing Remover/Installer tool, or equivalent. Tighten the expander assembly snug with the camshaft bearing.
^ Drive out the bearings.
21. Crankshaft Removal
a. Remove the main bearing cap studs and bolt.
b. Remove the main bearing caps and the lower bearing halves.
c. Remove the crankshaft.
d. Remove the upper bearing halves.
22. Cylinder Block Disassemble
a. Remove the knock sensor.
b. Remove the crankshaft position sensor retaining bolt.
c. Remove the crankshaft position sensor.
d. Remove the camshaft position sensor retaining bolt.
e. Remove the camshaft position sensor.
f. Remove the expansion plugs.