Part 2

Engine













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

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

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

NOTE: For additional information, refer to the exploded view in the Engine Engine - Assembly Assembly.

41. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.





42. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.

Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.





43. NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.





44. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.

Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.





45. NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, remove the 4 camshaft roller followers designated in the previous step from the LH cylinder head.





46. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.





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

Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.





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

Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.





49. Remove the LH and RH timing chain and the crankshaft sprockets.
- 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 the crankshaft sprocket.





50. Remove the 4 bolts and the timing chain guides.





51. Remove the bolts and the RH and LH camshaft sprockets.

52. Remove the balance shaft drive gear from the LH camshaft.





53. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.

Remove the 2 bolts and the RH camshaft front bearing cap.





54. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations or engine damage may occur.

Remove the 10 remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.





55. Clean and inspect the RH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.





56. Remove the RH camshaft.

57. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.

Remove the 2 bolts and the LH camshaft front bearing cap.





58. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations or engine damage may occur.

Remove the 10 remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.





59. Clean and inspect the LH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.





60. Remove the LH camshaft.

61. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.

Remove all of the remaining roller followers from the cylinder heads.

62. Remove the 2 bolts and the 2 Knock Sensor (KS)s.





63. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.

Remove the hydraulic lash adjusters from the LH cylinder head.

64. Install the Cylinder Head Remover/Installer onto the LH cylinder head.





65. Install the Cylinder Head Remover/Installer onto the RH cylinder head.





66. Remove the stud bolt and the coolant tube.
- Discard the O-ring seals.





67. NOTICE: 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.

NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine or engine damage may occur.

NOTICE: The cylinder head bolts must be discarded and new bolts must be installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.

NOTICE: 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.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface or cylinder head damage may occur.

NOTE: RH shown, LH similar.

Remove the 12 bolts and the cylinder heads.
- Discard the cylinder head gasket.

- Discard the cylinder head bolts.





68. NOTICE: 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.

NOTICE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep or engine damage may occur.

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 in the following sequence.

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.

69. NOTE: LH shown, RH similar.

Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.





70. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

Remove the 3 bolts and the LH engine support insulator bracket.

- Discard the 3 engine support bracket bolts.





71. NOTICE: 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.

NOTICE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep, or engine damage may occur.

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

Remove the 4 bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.





72. Remove the 12 bolts, the oil pan and discard the oil pan gasket.





73. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.





74. Remove the 3 bolts and the oil pump.





75. NOTICE: Make sure connecting rods and rod caps are numbered, to retain correct orientation.

Remove the 20 bolts and the connecting rod caps.

- Rotate the crankshaft so that the connecting rod is at bottom dead center.

- Remove and discard the bolts.





76. NOTICE: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod, or engine damage may occur.

Remove the piston and rod assembly.

- Using the Connecting Rod Installer, guide the piston and rod assembly out of the cylinder.





77. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.

78. Disassemble the 10 pistons. For additional information, refer to Piston Piston - Disassembly And Assembly.

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





80. Remove and discard the 12 bolts.





81. Remove the 12 main bearing cap dowel pins.





82. Remove the 6 main bearing caps, the lower crankshaft main bearings and the thrust washer.





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