Engine Disassemble
1. Draining Fluids and Remove Oil Filtera. Remove the oil pan drain plug. Allow the oil to drain.
b. Remove the oil filter.
c. Remove the engine block coolant drain plugs. Allow the coolant to drain.
d. Install the engine block coolant drain plugs.
^ Tighten the engine block coolant drain plugs to 20 Nm (15 ft. lbs.).
e. Install the oil pan drain plug.
^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.).
2. Remove Engine Flywheel
a. Remove the engine flywheel bolts.
b. Remove the engine flywheel.
3. Remove Oil Level Indicator and Tube
a. Remove oil level indicator from the tube.
b. Remove the oil level indicator tube bolt from the right cylinder head.
c. Remove the oil level indicator tube from the engine block.
4. Remove Right Side Exhaust Manifold
a. Remove the exhaust manifold bolts and studs.
b. Remove the spark plug heat shields.
c. Remove the exhaust manifold.
d. Remove and discard the gasket.
5. Remove Left Side Exhaust Manifold
a. Remove the EGR valve inlet pipe bolt and the clamp from the intake manifold.
b. Remove the EGR valve inlet pipe from the exhaust and intake manifolds.
c. Remove the exhaust manifold bolts and studs.
d. Remove the spark plug heat shields.
e. Remove the exhaust manifold.
f. Remove and discard the gasket.
6. Remove Water Pump
a. Remove the bypass hose and clamps.
b. Remove the bolts.
c. Remove the water pump.
d. Remove and discard the gaskets.
7. Remove Crankshaft Balancer
^ Tools Required
- J 23523 Crankshaft Balancer Remover and Installer, Or Equivalent
a. Remove the crankshaft balancer bolt and the washer.
b. Use the crankshaft balancer remover in order to remove the crankshaft balancer.
8. Remove Distributor
a. Remove the distributor clamp bolt.
b. Remove the distributor clamp.
c. Remove the distributor from the engine block.
9. Remove Intake Manifold
NOTE: Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.
a. Remove the PCV valve and the vacuum hose.
b. Remove the EGR valve inlet tube from the intake manifold.
c. Remove the oxygen sensor wire support bracket and the nut from the intake manifold.
d. Remove the canister purge system tubing.
NOTE: Do not reuse the lower intake manifold gaskets.
e. Remove the lower intake manifold bolts.
f. Remove the intake manifold.
g. Remove and discard the intake manifold gaskets.
10. Remove Valve Rocker Arm Cover
a. Remove the valve rocker arm cover bolts.
b. Remove the valve rocker arm cover.
c. Remove and discard the gasket.
11. Remove Valve Rocker Arm and Push Rod
a. Remove the following components from the cylinder head
1. The valve rocker arm nuts (1)
2. The valve rocker arm balls (2)
3. The valve rocker arms (3)
b. Remove the valve pushrods.
c. Place the following parts in a rack so that they can be reinstalled in their original locations
^ The valve rocker arms
^ The valve rocker arm balls
^ The valve pushrods
12. Remove Remove Valve Lifter
^ Tools Required
- J 3049 Valve Lifter Remover (Plier Type)
- J 92901 Valve Lifter Remover (Slide Hammer Type)
- Or Equivalents
a. Remove the valve lifter guide retainer and bolts.
b. Remove the valve lifter guides.
c. Place the components in a rack so that they can be reinstalled to their original location.
NOTE: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use the valve lifter remover in order to remove these valve lifters.
d. Use the valve lifter remover in order to remove the valve lifters.
e. If the valve Inters cannot be removed with the valve lifter remover in order to remove the valve lifters.
13. Remove Cylinder Head
a. Remove the cylinder head bolts.
CAUTION: After removal, place the cylinder head on two wood blocks to prevent damage.
b. Remove the cylinder head.
c. Remove and discard the gasket.
14. Remove Oil Filter Adapter and Valve Assembly
a. Remove the oil filter adapter bolts.
b. Remove the oil filter adapter, oil seal and gasket.
15. Remove Remove Oil Pan
a. Remove the following oil pan components
1. Bolts
2. Nuts
3. Studs
b. Remove the oil pan reinforcements.
c. Remove the oil pan.
d. Remove and discard the oil pan gasket.
16. Remove Oil Pump
a. Remove the crankshaft oil deflector nuts (6) and deflector (2).
b. Remove the bolt (1) that attaches the oil pump to the rear crankshaft bearing cap.
c. Remove the oil pump (3), the driveshaft (5), and the retainer (4).
17. Remove Engine Front Cover
a. Remove the engine front cover bolts.
NOTE: Do not reuse the composite front cover and gasket. A new front cover and gasket must be used.
b. Remove the engine front cover and gasket.
18. Remove Timing Chain and Sprockets
^ Tools Required
- J 5825 A Crankshaft Gear Puller, Or Equivalent
CAUTION: Do not rotate the crankshaft after the timing chain is removed. The pistons and the valves may be damaged.
a. Measure the camshaft timing chain free play. If the chain can be moved back and forth in excess of 16 mm (0.625 inch) replace the camshaft timing chain and the sprockets during reassembly.
b. Remove the camshaft sprocket bolts.
c. Remove the camshaft sprocket.
d. Remove the camshaft timing chain.
e. Remove the crankshaft sprocket using the crankshaft gear puller.
f. Remove the key, if necessary.
19. Remove Camshaft
a. Remove the camshaft retainer bolts and retainer.
NOTE: All camshaft journals are the same diameter, so care must be used in removing the camshaft to avoid damage to the bearings.
b. Remove the camshaft.
1. Install the three 5/16 18 x 4.0 inch bolts in the camshaft front bolt holes.
2. Carefully rotate and pull the camshaft out of the bearings.
20. Remove Piston, Connecting Rod, and Bearing
^ Tools Required
- J 5239 Guide Set, Or Equivalent
a. Remove the ring ridge.
1. Turn the crankshaft until the piston is at the bottom of the stroke.
2. Place a cloth on top of the piston.
3. Use a ridge reamer to remove cylinder ring ridge.
4. Turn the crankshaft so the piston is at the top of the stroke.
5. Remove the cloth.
6. Remove the cutting debris.
NOTE: Place matchmarks or numbers on the connecting rods and the connecting rod caps. Assemble the connecting rod caps to the matching connecting rods.
b. Remove the connecting rod nuts.
c. Remove the connecting rod cap.
d. Remove the connecting rod bearings Keep the bearings with the original connecting rod and connecting rod cap.
^ Wipe the oil from the bearings.
^ Wipe the oil from the crankpins.
e. Use the guide set in order to remove the connecting rod and the piston out of the top of the engine block.
21. Remove Crankshaft Rear Oil Seal and Housing
a. Remove the crankshaft rear oil seal housing nuts and bolts.
b. Remove the crankshaft rear oil seal housing, seal, and gasket.
c. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing.
d. Discard the gasket and seal.
22. Remove Crankshaft, Bearings, and Bearing Cap
a. Remove the crankshaft bearing cap bolts and studs.
b. Remove the crankshaft bearing caps.
c. Remove the crankshaft.
d. Remove the crankshaft bearings from the bearing caps and from the engine block.
23. Remove Cylinder Block Plug
a. Remove the engine block coolant plugs.
b. Remove the front engine block oil gallery plugs.
c. Remove the rear and side engine block oil gallery plugs.