Disassembly

1. Remove the engine assembly.





2. Remove the oil pan retaining bolts and oil pan.





3. Remove the oil pump screen cover and tube screws and retaining nut. Remove the oil pump screen cover and tube.
4. Remove the water pump.





5. Remove the crankshaft damper bolt and washer and using the Crankshaft Damper Tool, remove the crankshaft vibration damper.
6. Remove the high-pressure oil pump oil reservoir.





7. Remove the oil pump housing bolts and the oil pump body plate and square-cut O-ring.





8. Remove the inner gerotor.
9. Remove the bolts retaining the front header of the oil cooler to the engine timing cover.





10. Remove the engine timing cover bolts, the front cover and the gaskets.
11. Remove the cylinder heads.

CAUTION: Do not use a power wrench for removing or installing connecting rod bolts, connecting rod nuts and washers. Power wrench usage will cause seizure of the connecting rod bolt or connecting rod nut threads.





12. Remove any ridges or deposits from the upper ends of the cylinder bores as follows:
1 Turn the crankshaft until the piston to be removed is at Bottom Dead Center (BDC). Place a cloth on the piston head to collect cuttings. Remove any ridges or deposits from the upper end of the cylinder bore.
2 Remove the cylinder ridge with a razor knife or equivalent. Carefully scrape the ridge away.

13. Mark all the connecting rods and connecting rod caps to permit installation into original positions.





14. Remove the connecting rod nuts and connecting rod cap.





15. Push the connecting rod and piston out through the top of the cylinder with the handle end of a hammer. Avoid damage to the piston cooling oil jets, crankshaft journal or cylinder wall when removing the piston and connecting rod.

NOTE: Install rubber hose or equivalent onto the connecting rod bolts.

16. Remove the connecting rod bearings from the connecting rod and connecting rod cap.
17. Install the connecting rod cap onto the connecting rod from which it was removed.
18. Remove the valve tappets.





19. Rotate the crankshaft to align the camshaft sprocket and crankshaft sprocket timing marks.





20. Remove the camshaft thrust plate retaining bolts.





21. Remove the camshaft, camshaft sprocket and camshaft thrust plate as an assembly.





22. Using a suitable press, remove the camshaft drive gear, thrust plate and sprocket key from the camshaft.
23. Inspect the camshaft lobes and journals for:
- wear
- scoring





24. Remove the main bearing cap bolts and main bearing caps.





25. Remove the crankshaft from the cylinder block.

CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.

26. Clean the oil pan mating surfaces and the oil pump screen cover and tube mating surfaces.
27. Inspect the oil pan and the oil pump screen cover and tube for damage.
28. Clean the engine timing cover, oil pan and cylinder block mating surfaces.