Disassembly

Special Tools:

1. Remove the flywheel and engine rear plate and mount the engine on a suitable work stand.





2. Remove the A/C support bracket and A/C compressor mounting bracket.





3. Remove the water pump pulley.





4. Remove the drive belt idler pulley.





5. Remove the generator mounting bracket.





6. Remove the engine oil cooler inlet tube and hose and engine oil cooler outlet tube and hose (if so equipped).





7. Remove the engine mounts.





8. Remove the Heated Oxygen Sensors (HO2S) (left side shown; right side similar).





9. Remove the engine lifting eyes (left side shown; right side similar).





10. Remove the oil level indicator tube.





11. Remove the exhaust manifolds (left side shown; right side similar). Discard the gaskets.





12. Remove the valve covers (left side shown; right side similar).

13. Note: The location of each rocker arm seat, rocker arm and push rod should be identified. When the engine is assembled, each component should be installed in its original position.





Remove the rocker arms, rocker arm seats and push rods.





14. Remove the cylinder heads and head gaskets (left side shown; right side similar). Discard the head gaskets and bolts.

15. Note: Identify the location of each valve tappet. When the engine is assembled, make sure each valve tappet is installed in its original position.





Remove the tappet guide plates and retainers and valve tappets.





16. Remove the heater water outlet tube.





17. Remove the camshaft synchronizer.

18. Note: The crankshaft pulley and damper are a balanced assembly. Mark the components for alignment before removal.





Remove the crankshaft pulley.





19. Remove the bolt and the crankshaft damper.
- A puller will be needed to remove the damper from the crankshaft.





20. Remove the oil bypass filter and the engine oil cooler (if so equipped).





21. Remove the oil pan and the oil pan rear seal.





22. Remove the oil pump screen cover and tube. Discard the oil pan gasket.





23. Remove the oil pan baffle.





24. Remove the engine front cover. Discard the engine front cover gasket.





25. Remove the following:
1. synchronizer drive gear
2. camshaft sprocket
3. crankshaft sprocket
4. timing chain
5. engine dynamic balance shaft





26. Remove the timing chain vibration damper.





27. Remove the engine dynamic balance shaft.





28. Remove the camshaft.

29. Note: Mark the location of each piston, connecting rod bearing and connecting rod cap. When the engine is assembled, each component should be installed in its original position.





Inspect the top of each cylinder bore and, if necessary, remove the ridge or carbon deposits. Remove the pistons.





30. Remove the crankshaft and main bearings. Discard the crankshaft rear oil seal.