Disassembly
Engine
Special Tool(s)
Disassembly
1. Disconnect the spark plug wires.
2. Disconnect the vacuum line.
3. Disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.
4. Disconnect the ignition coil.
5. Disconnect the EGR solenoid electrical connector and vacuum line.
6. Remove the bolts and remove the ignition coil assembly.
7. Remove the bolts and the generator mounting bracket.
8. Remove the A/C compressor bracket bolt and nut.
9. Remove the bolts and the A/C compressor mounting bracket (2882).
10. Remove the four bolts and the water pump pulley.
11. Remove the bolts and the crankshaft pulley.
12. Remove the crankshaft damper bolt.
13. Using a Crankshaft Vibration Damper Remover, remove the crankshaft damper.
14. Disconnect the engine control sensor wiring from:
- the Idle Air Control (IAC) valve.
- the Throttle Position (TP) sensor.
- the EGR transducer.
15. Disconnect the EGR solenoid vacuum tube from the upper intake manifold port.
16. Remove the 42-pin connector from the bracket and position out of the way.
17. Mark and disconnect the EGR transducer hoses.
18. Remove the Positive Crankcase Ventilation (PVC) from the valve cover.
19. Loosen the bottom nut and remove the top bolt. Position the intake manifold support bracket out of the way.
20. Remove the bolt and position the Exhaust Gas Recirculation Valve (EGR) vacuum regulator valve out of the way.
21. Remove the five bolts and remove the upper intake manifold.
22. Remove the intake manifold upper gasket.
23. Disconnect the engine control sensor wiring from:
- the Engine Coolant Temperature (ECT) sensor.
- the water temperature indicator sender unit.
- the fuel injectors.
- the camshaft synchronizer.
24. NOTE: To prevent stretching the valve cover gasket, loosen silicone gasket and sealant from the cylinder head by sliding a flat knife between the valve cover gasket and cylinder head.
Remove the valve covers.
25. If necessary, remove the valve cover gaskets.
26. Clean the sealing surfaces.
27. Remove the rocker arms and the push rods.
28. Remove the lower intake manifold.
- Remove the eight bolts.
- Remove the lower intake manifold.
29. Remove and discard the intake manifold gaskets and end seals.
30. Clean the sealing surfaces.
31. Remove the camshaft synchronizer.
32. Remove the oil pan.
- Remove the bolts.
33. Remove the oil pan gasket.
34. Clean the surfaces.
35. Remove the Crankshaft Position (CKP) sensor.
36. Remove the engine front cover.
- Remove the ten bolts.
37. Remove the engine front cover gasket.
38. Clean the sealing surfaces.
39. Remove the EGR valve to exhaust manifold tube.
40. Remove the oil level indicator tube.
41. Remove the oil filter.
42. Remove the bolts.
43. Remove the cylinder heads.
44. Remove the head gaskets.
45. Remove the valve tappet guide plate retainer.
46. Remove the valve tappet guide plates.
47. NOTE: The valve tappets are positional. Identify each valve tappet for installation in the original position.
Remove the valve tappets.
48. Align the timing marks.
49. Remove the bolt.
50. Remove the timing sprockets and the timing chain/belt as an assembly.
51. Remove the camshaft retainer.
52. Remove the camshaft.
53. If required, remove the camshaft bearings.
- Use the Camshaft Service Set.
54. Remove the oil pump.
55. NOTE: Before removing the piston and connecting rod assemblies, inspect the top of the cylinder bores. If necessary remove the cylinder ridge.
Remove the piston and connecting rod assemblies one at a time.
- Remove the connecting rod nuts in pairs.
- Remove the connecting rod cap.
- Remove the piston and connecting rod assembly.
56. Remove the bolts.
57. Remove the main bearing caps.
58. Remove the lower crankshaft main bearings.
59. Remove the crankshaft rear oil seal.
60. Remove the crankshaft.
61. Remove the upper crankshaft main bearings.