Disassembly

Engine








Special Tool(s)

NOTE: The crankshaft rear oil seal, the oil seal slinger and the oil seal retainer plate must be removed before mounting the engine on the engine stand.

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, nut and the oil pump screen cover and tube.





4. NOTE: LH shown; RH similar.

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

Fully loosen the sixteen bolts, and remove the valve cover and the valve cover gasket.





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





6. Remove the bolts.





7. Remove the water pump from the cylinder block.





8. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.





9. Using the special tool, remove the crankshaft front seal.





10. Remove the bolt and the belt idler pulley.





11. Remove the engine front cover fasteners.





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





13. Remove the crankshaft sensor ring from the crankshaft.








14. CAUTION: The bearing caps must be marked for installation in their original location or engine damage can occur.

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





15. 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.

Position the crankshaft with the keyway at the 12 o'clock position.





16. Install the special tools on the camshafts.





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





18. 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.

Remove the LH and RH timing chain and the crankshaft sprockets.
^ Remove the Crankshaft Holding Tool.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Remove the LH timing chain from the camshaft sprocket.
^ Remove the LH timing chain and crankshaft sprocket.





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





20. Remove the 10 nuts and the RH exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket.





21. Remove the 10 nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.





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





23. Install the special tools on both ends of the cylinder head.





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

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

25. 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.

Clean and inspect the cylinder head surface.
26. Remove 1he 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. CAUTION: Make sure connecting rods and rod caps are numbered, to keep in correct orientation.

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.





30. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
Remove the piston and rod assembly.

Using the special tools to guide the piston and rod assembly out of the cylinder.
31. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.





32. Remove and discard the 12 cross-mounted bolts.





33. Remove and discard the bolts.





34. Remove the main bearing cap dowel pins.





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





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