All
TOOL REQUIRED^ J 8062 Valve Spring Compressor
^ J 38821 Valve Spring Compressor Adapter
^ J 38819 Valve Keeper Installer
^ J 38820 Valve Stem Seal Installer
^ J 38825 Water Pump Drive Pulley Remover
^ J 39411 Flex plate Holder
^ J 38416 Harmonic Balancer Remover
^ J 39344 Harmonic Balancer Installer
^ J 38816-1A Water Pump Remover/Installer
PROCEDURE
1. Drive Belt Removal
a. Insert a 1/2-inch drive ratchet in the drive belt tensioner.
b. Rotate the drive belt tensioner counter clockwise in order to release the belt tension.
c. Remove the drive belt from the power steering pulley.
d. Slowly return the drive belt tensioner to its original position.
e. Remove the drive belt from the remaining pulleys.
f. Remove the drive belt tensioner pulley retaining bolt.
g. Remove the drive belt tensioner bolt and tensioner.
h. Remove the accessory belt idler pulley.
2. Power Steering Pump Removal
a. Remove the power steering pump retaining bolt. The bolt is located perpendicular to the crankshaft centerline and behind the power steering pulley.
b. Remove the power steering pump.
3. Generator Removal
a. Remove the generator retaining bolts located at the front and rear of the generator.
b. Remove the generator.
c. Remove the rear generator mounting bracket retaining bolts.
d. Remove the rear generator mounting bracket.
4. Air Conditioning Compressor Removal
a. Remove the five air conditioning compressor mounting bolts. Three bolts are located at the front of the compressor. Two bolts are located at the rear of the compressor.
b. Remove the air conditioning compressor.
c. Remove the air conditioning compressor mounting bracket bolt.
d. Remove the air conditioning compressor mounting bracket.
5. Oil Filter Adapter Removal
a. Remove the oil filter.
b. Remove the oil filter adapter mounting bolts.
c. Remove the oil filter adapter and discard the O-ring seals.
d. Remove the oil pressure switch (if necessary).
6. Intake Manifold Removal
a. Remove the intake manifold sight shield. Refer to Engine Cover Replacement
b. Disconnect the PCV valve and both feed tubes from the camshaft covers.
c. Disconnect the EGR and crankcase ventilation pipe at the throttle body spacer.
d. Disconnect the fuel rail ground wire at the rear cylinder head.
e. Disconnect the fuel rail bracket at the EGR valve.
f. Loosen and remove the intake manifold bolts.
g. Remove the intake manifold assembly.
CAUTION: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When you remove the intake manifold, the carrier gaskets will remain attached to the manifold. it is not necessary to replace the gaskets unless there is damage to the seals.
7. Exhaust Manifold Removal (Left)
a. Remove the oil level indicator.
b. Remove the oil level indicator tube retaining bolt.
c. Remove the oil level indicator tube.
d. Disconnect the left exhaust manifold (3) from the crossover pipe (1).
e. Remove the exhaust manifold bolts.
f. Remove the exhaust manifold and the gasket. Do not reuse the gasket.
g. Remove the oxygen sensor and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary.
8. Exhaust Manifold Removal (Right)
a. Disconnect and remove the exhaust crossover pipe (1).
b. Remove the right exhaust manifold retaining bolts.
c. Remove the exhaust manifold and the gasket. Do not reuse the gasket.
d. Remove the oxygen sensor and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary.
9. Ignition Module Removal
a. Disconnect the spark plug wires from the spark plugs.
b. Remove the ignition system module retaining bolts from the right (rear) camshaft cover.
c. Remove the ignition system module from the camshaft cover with the spark plug wires attached.
10. Camshaft Cover Removal (Left)
a. Remove the EGR feed tube from the water crossover.
b. Remove the water pump drive belt shield retaining nuts.
c. Remove the water pump drive belt shield.
d. Remove the water pump drive belt by compressing the belt tensioner (1) while sliding the belt off the drive pulley.
e. Remove the water pump drive pulley from the intake camshaft. Use the Water Pump Drive Pulley Remover.
f. Remove the camshaft seal retaining screws and the seal.
g. Remove the camshaft cover bolts.
h. Remove the camshaft cover using the following steps:
i. Lift up the front of the cover approximately 10 inches.
j. Lift the rear exhaust edge while holding the front suspended.
k. Swing the front of the cover over the intake manifold while sliding the entire cover over the end of the camshaft.
l. The camshaft cover seals (perimeter and sparkplug) should be reused unless they are damaged or if the perimeter seal is pulled from its groove during removal.
11. Camshaft Cover Removal (Right)
a. Remove the camshaft cover bolts.
b. Remove the camshaft cover.
c. The camshaft cover seals (perimeter and sparkplugs) should be reused unless they are damaged or if the perimeter seal is pulled from its groove during removal.
12. Crankshaft Balancer Removal
a. Secure the flex plate in order to prevent crankshaft rotation. Use the flex plate holder. Remove the crankshaft balancer bolt.
c. Place the harmonic balancer installer in the end of the crankshaft.
d. Position the ends of the legs of the harmonic balancer remover onto the backside of the balancer inner hub.
e. Tighten the center screw on the puller until the balancer pulls clear of the crankshaft end.
f. Remove the crankshaft balancer.
13. Engine Front Cover Removal
a. Remove the front cover perimeter bolts.
b. Remove the front cover and the gasket. Make sure you do not damage the sealing surface.
14. Front Crankshaft Oil Seal Removal
a. Using two blocks of wood, evenly support the front cover with the outside surface downward.
b. Remove the front cover seal using a pry bar or screwdriver in order to pry out the seal. The seal should remove easily. Be careful not to gouge the front cover when prying out the front cover seal.
15. Secondary Camshaft Drive Chain Removal
a. Loosen both of the drive chain tensioner bolts.
b. Remove the tensioner bolts and the tensioner allowing the tensioner to expand as you remove it.
c. Remove the chain guide access plugs located in the cylinder heads. Note the O-ring seal on each access plug.
d. Remove the camshaft position sensor.
e. Remove the camshaft sprocket retaining bolts.
f. Slide the camshaft sprockets off of the camshafts.
g. Remove the camshaft sprockets and the secondary drive chain together. Leave the intermediate sprocket in place.
h. Remove the secondary chain guide retaining bolts.
i. Remove the secondary chain guides.
16. Oil Pump Removal
a. Remove the oil pump assembly retaining bolts identified by the larger head size.
b. Remove the oil pump assembly with the drive collar in place.
17. Primary Camshaft Drive Chain Removal
a. Remove the intermediate sprocket retaining bolt.
b. Remove the primary drive chain tensioner.
c. Remove the primary chain drive sprocket, the primary chain and the intermediate sprocket as an assembly.
d. Remove the intermediate sprocket shaft retaining bolts.
e. Remove the intermediate sprocket shaft.
f. Remove the crankshaft drive key. Do not damage the crankshaft.
18. Camshaft Removal
a. Remove the camshaft bearing cap bolts.
b. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings:
^ The arrow points toward the front of the engine.
^ The I indicates the intake camshaft.
^ The E indicates the exhaust camshaft.
^ The number indicates the journal position from the front of the engine.
c. Remove the camshaft bearing caps. Store the bearing caps in a clean shop towel.
d. Remove the camshaft. Place the camshaft in a secure location.
e. Cover the camshaft with an oil soaked towel in order to prevent corrosion.
f. Repeat the procedure for each camshaft.
19. Valve Lifter Removal
a. Using a marker, mark the location of each valve lifter. Use the following coding for marking the valve lifters:
^ Cylinder number
^ Follow the cylinder number with I for intake or E for exhaust
^ Valve number, 1 or 2, from the front of the engine
^ For example, 3E1 would be defined as number three cylinder, first exhaust valve from the front of the engine.
b. Prepare a clean piece of cardboard to place the lifters on.
c. Remove the lifters and place them on the cardboard.
d. Secure the cardboard and the followers in order to prevent damage or contamination.
20. Thermostat Removal
a. Remove the thermostat housing retaining bolts.
b. Remove the thermostat housing and the thermostat.
21. Water Pump Removal
a. Remove the water pump housing bolts.
b. Remove the water pump housing and the gasket.
c. Remove the water pump from the water crossover. Use the Water Pump Remover/Installer. Index the Water Pump Remover/Installer into the water pump locking ears and twist in order to unlock the pump from the housing.
22. Water Crossover Removal
a. Remove the EGR valve bolts.
b. Remove the EGR valve and the gasket.
c. Remove the water crossover mounting bolts.
d. Remove the water crossover.
e. Remove the water crossover gaskets. Do not damage the water crossover gaskets. These gaskets are reusable.
23. Cylinder Head Removal
a. Remove the coolant temperature sensor.
b. Remove the three M6 external drive bolts from the front portion of the cylinder head.
c. Remove the ten M11 internal drive cylinder head bolts.
d. Remove the cylinder head. Make sure that no dowel guide pins are stuck in the cylinder head.
e. Remove the cylinder head gasket. Make sure all of the gasket material is removed.
f. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in order to prevent damage to the deck face.
g. Remove the oil gallery plugs at the front and rear of the cylinder head.
24. Valve Removal
a. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer in order to loosen the valve keepers.
b. Compress the valve spring with the Valve Spring Compressor and the Valve Spring Compressor Adapter.
c. Use the magnetic end of the Valve Keeper Installer in order to remove the valve keepers.
d. Remove the valve spring compressor and the pilot.
e. Remove the valve spring.
f. Remove the valve seal. Use the Valve Stem Seal Installer.
g. Remove the valve.
h. Repeat the procedure for the remaining valves.
25. Starter Motor Removal
a. Disconnect the knock sensor wire lead.
b. Remove the knock sensor.
c. Remove the two starter motor retaining bolts.
d. Using two hands, remove the starter motor and the wiring harness by sliding the motor toward the front of the engine. Leave the wiring harness attached unless replacing the starter.
26. Engine Flex plate Removal
a. Rotate the engine so that the main bearing bolts are facing up.
b. Hold the flex plate in order to prevent rotation.
c. Loosen the eight flex plate mounting bolts.
d. Remove seven of the eight flex plate mounting bolts leaving one bolt at the top of the crankshaft rotation.
e. Grip the flex plate and remove the remaining bolt. Do not drop the flex plate when removing the final bolt.
27. Oil Pan Removal
a. Rotate the engine so that the oil pan is facing up.
b. Remove the oil pan bolts.
c. Lift the oil pan from the lower crankcase.
d. Remove the oil pump pickup tube retaining nut from the main bearing stud.
e. Remove the retaining bolt from the oil manifold plate.
f. Remove the oil pump pickup tube.
g. Remove the oil level sensor.
28. Lower Crankcase Removal
a. Remove the two crankshaft position sensors.
b. Remove the lower crankcase perimeter retaining bolts.
c. Remove the main bearing bolts. Note the location of the single stud-end bolt (1) used to attach the oil pump pickup.
d. Remove the oil scraper plate.
CAUTION: Use a plastic pry tool when prying case halves apart to prevent damage to the Upper and Lower Crankcase surface. Do not continue to push the pry tool in the crankcase as the Upper and Lower Crankcase halves separate. This may damage the sealing surface.
e. Working on either side of the lower crankcase, separate the crankcase halves by alternately prying in the grooves provided until the lower crankcase is free of the dowel pins.
f. Remove the lower crankcase.
g. Inspect the upper-to-lower crankcase seal. The upper-to-lower crankcase seal may be reused unless it is damaged or comes out of its groove in the upper crankcase.
h. Try to save the seal for inspection procedures.
i. Remove and discard the rear main seal from the end of the crankshaft.
29. Connecting Rod, Bearing, and Piston Removal
a. Before removing the connecting rods, check the connecting rod end play using the following procedure:
^ Tap the connecting rod to one end of the crankshaft journal.
^ Using feeler gages, measure the clearance between the crankshaft counterweight and the connecting rod.
^ The connecting rod end play should not exceed 0.050 mm (0.020 inch).
^ If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod.
^ The width of the crankpin end of the connecting rod should be 21.745-21.805 mm (0.856-0.858 inch).
^ If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.
^ If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
b. Using a marker, number each piston face. Draw an arrow along the centerline of the piston pin pointing toward the front of the engine.
c. Mark the cylinder number on the connecting rod and the connecting rod cap with scribe or marker. The connecting rod caps must remain with the original connecting rod.
CAUTION: Powdered metal connecting rods have rod bolts which yield when torqued. If the rod bolts are removed, replace the rod bolts.
d. Remove the connecting rod bolts. Discard the bolts.
e. Remove the connecting rod cap.
f. Push the connecting rod and the piston assembly down through the top of the cylinder. Do not scratch the crankshaft journal or the cylinder wall when removing the connecting rod and the piston assembly.
30. Crankshaft Removal
a. Before removing the crankshaft, measure the crankshaft end play. Use the following procedure:
^ Reinstall the lower crankcase.
^ Place a dial indicator at the crankshaft nose.
^ Gently force the crankshaft to the extreme front and rear positions with a pry tool while monitoring the movement of the dial indicator.
^ The crankshaft end play should not exceed 0.05-0.5 mm (0.002-0.020 inch).
^ If the specifications are exceeded, replace the thrust bearing.
^ If a new thrust bearing does not bring the tolerances within specification, replace the crankshaft.
^ Remove the lower crankcase.
b. Locate or fabricate two V-blocks to support the crankshaft.
c. Using two hands, lift the crankshaft straight up from the engine block.
d. Place the crankshaft on the V-blocks in a secure place.
31. Crankshaft Bearing Removal
a. Prepare a piece of cardboard, or equivalent, numbered one to five for bearing identification. Main bearing journals are numbered from the front of the engine.
b. Remove the upper main bearing halves from the upper crankcase.
c. Place the upper main bearing halves on the cardboard in the correct positions. Note that the number three bearing is the thrust bearing.
d. Remove the lower main bearing halves from the lower crankcase.
e. Place the lower main bearing halves in the correct positions on the cardboard.