Disassembly

Engine








Special Tool(s)





Material

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: For additional information, refer to the exploded views under engine Assembly.

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





1. Remove the bolts and the flexplate or the flywheel.





2. Remove the spacer plate.





3. Using the special tools, remove the crankshaft rear oil slinger.





4. Using the special tools, remove the crankshaft rear seal.





5. Remove the bolts, oil pan and oil pan gasket.
- Clean and inspect the sealing surfaces.





6. Remove the bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.

7. Mount the engine on a suitable work stand.





8. Disconnect the oil pressure sensor electrical connector.





9. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.





10. Disconnect the camshaft position (CMP) sensor electrical connector.





11. Disconnect the crankshaft position (CKP) sensor electrical connector.





12. Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.





13. Disconnect the RH radio ignition interference capacitor electrical connector.
14. Disconnect the engine wiring harness retainers from the valve cover studs and remove the electrical harness from the engine assembly.





15. Remove the nut and the upper radiator hose bracket.





16. NOTE: RH shown, LH similar.

Remove the nuts and the 2 radio interference capacitors.





17. Remove the bolt and the CMP sensor.





18. Remove the bolt and the CKP sensor.





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

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

NOTE: LH shown, RH similar.

Remove the valve covers.
- Fully loosen the bolts and remove the valve covers.
- Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.





20. Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.





21. Remove the bolts and the accessory drive belt tensioner.





22. Remove the bolts.





23. Remove the coolant pump from the cylinder block.





24. Remove and discard the crankshaft pulley bolt.

Use the special tool to remove the crankshaft pulley.





25. Use the special tool to remove the crankshaft front seal.





26. NOTE: Correct fastener location is essential for assembly procedure. Record the fastener location.

Remove the fasteners.





27. Remove the engine front cover from the cylinder block.





28. NOTE: Camshaft roller follower is shown removed for clarity.

Install the special tool between the valve spring coils to prevent valve stem seal damage.





29. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.

NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.

Using the special tool, compress the valve springs and remove the camshaft roller follower.

30. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.

Repeat the previous 3 steps for each camshaft roller follower.





31. Remove the crankshaft sensor ring from the crankshaft.





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





33. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seat integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.





34. Remove the timing chains and crankshaft sprocket.





35. Remove the timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.





36. Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the RH exhaust manifold.
3. Remove and discard the RH exhaust manifold gasket.





37. Remove the LH exhaust manifold.
1. Remove the nuts.
2. Remove the LH exhaust manifold.
3. Remove and discard the LH exhaust manifold gasket.

38. Clean and inspect the exhaust manifolds.





39. Remove the bolt and the oil level indicator tube.





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





41. CAUTION: The cylinder head must be cool before removing it from the engine.

Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

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

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: LH shown, RH similar.

Remove the bolts and the cylinder heads.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.

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

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.





43. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61-cm (24 inch) long, the machine edge must be flat with 0.010 mm (0.0004 inch) from end to end.

NOTE: LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1-mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).





44. Remove the bolts and the RH engine support insulator.





45. Remove the bolts and the LH engine support insulator.





46. Remove the bolts and the oil filter adapter.
- Discard the gasket.





47. Clean the gasket surfaces at the cylinder block and the oil filter adapter.





48. Remove the bolts, the oil pump screen and pickup tube and the spacer.





49. Remove the 3 bolts and the oil pump.
50. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer instructions.





51. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.

Remove the bolts and the connecting rod caps. Discard the bolts.





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

Use the special tool to push the piston through the top of the cylinder block.
53. Disassemble the 8 pistons.





54. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

Remove the crankshaft bearing cap fasteners.
1. Remove and discard the cross-mounted main cap bolts.
2. Loosen the Jack screws.
3. Remove and discard the main cap bolts.





55. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.





56. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.