Disassembly

1. With the engine on the engine stand, remove the engine wiring harness.





2. Remove the bolts, the oil pan, and the oil pan gasket.





3. Remove the two bolts and nut retaining the oil pump screen cover and tube and remove the oil pump screen cover and tube.





4. LH is shown; RH is similar.
- Fully loosen the sixteen bolts, and remove the valve cover and the valve cover gasket

NOTE: The bolts are a part of the valve cover and are not to be removed.





5. Remove the bolts, and set aside the power steering pump.





6. Remove the water pump pulley.
1 Remove the bolts.
2 Remove the water pump pulley.





7. Remove the bolts.





8. Remove the (A) water pump from the (B) cylinder block.





9. Remove the crankshaft pulley bolt. Use the Crankshaft Damper Remover to remove the crankshaft pulley.





10. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal.





11. Remove the engine timing cover fasteners.

12. Remove the engine timing cover from the front cover to cylinder block dowels.








13. Remove the crankshaft sensor ring from the crankshaft.





14. Remove the six bolts, the bearing caps and the balance shaft.





15. Position the crankshaft with the Crankshaft Holding Tool as shown.

CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.





16. Install the Camshaft Holding Tools on the camshafts.





17. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins.





18. Remove the LH and RH timing chain/belts and the crankshaft sprockets.
- Remove the Crankshaft Holding Tool.
- Remove the RH timing chain/belt from the camshaft sprocket.
- Remove the RH timing chain/belt and outer crankshaft sprocket from the crankshaft.
- Repeat for the LH timing chain/belt and crankshaft sprocket.

CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.





19. Remove the timing chain guides.
- Remove the bolts.
- Remove the timing chain guides.





20. Remove the ten nuts and the RH exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket.





21. Remove the ten nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.





22. Remove the oil level dipstick, the bolt and the oil level indicator tube.





23. Install the Lifting Handles on both ends of the cylinder head.





24. Remove the bolts and the cylinder head.
- Discard the head gasket and clean the engine block surface.
- LH is shown; RH is similar.

CAUTION: These bolts must be replaced with new bolts. They are tighten-to-yield designed and cannot be reused.

25. Clean and inspect the cylinder head surface.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the cylinder head. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of oil sealant.

26. Remove the bolts and remove the engine mounts.





27. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.





28. Remove the bolts and the oil pump.





29. Remove the twelve bolts and the two lower crankshaft bearing supports.





30. Remove the bolts and the connecting rod caps.
- Rotate the crankshaft so that the connecting rod is at bottom dead center.
- Remove the bolts and discard them.

CAUTION: Make sure connecting rods and rod caps are numbered, to keep in proper orientation.





31. Remove the piston and rod assembly.
- Use the Connecting Rod Guide Tools to guide the piston and rod assembly out of the cylinder.

CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

32. Repeat the previous steps until all ten piston and rod assemblies have been removed from the cylinder block.





33. Remove and discard the twelve cross-mounted bolts.





34. Remove and discard the bolts.





35. Remove the main bearing cap dowel pins.





36. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.





37. Remove the crankshaft and the crankshaft main bearings from the cylinder block.