Disassemble

1. Draining Fluids and Oil Filter Removal:
a. Remove the oil pan drain plug and allow oil to drain from the oil pan.
b. Remove the oil filter.
c. Remove coolant jacket drain plugs and allow coolant to drain from cooling jacket.
d. Install oil pan drain plug and the coolant jacket plugs.
^ Reinstall the oil pan drain plug.
^ Oil Pan Drain Bolt to 45 Nm (33 ft. lbs.).
^ Reinstall the coolant jacket drain plugs.
^ Coolant Jacket Plugs to 15 Nm (11 ft. lbs.).
e. If cleaning or repairing engine block it is not necessary to reinstall the plugs.





2. Engine Flywheel Removal:
a. Remove the flywheel bolts.
b. Remove the flywheel spacer if a flywheel spacer is used. Important: If the flywheel is cracked or damaged replace the flywheel.
c. Remove the flywheel.





3. Oil Level Indicator and Tube Removal:
a. Remove the oil level indicator.
b. Remove the oil fill tube bolt.
c. Remove the oil fill tube.
d. Remove the oil fill tube seal.





4. Exhaust Manifold Removal:
a. Remove the Oxygen sensor from the exhaust manifold to prevent damage to the sensor.
b. Remove the exhaust manifold nuts.





c. Remove the exhaust manifold.
d. Remove the exhaust manifold gasket.





5. Water Pump Removal:
a. Remove the coolant pump drive pulley and bolts.
b. Remove the coolant pump attaching bolts.
c. Remove the coolant pump.





d. Remove the coolant pump gasket.
^ Clean all sealing surfaces
^ Inspect all sealing surfaces for burrs or imperfections





6. Crankshaft Pulley Removal Procedure:
a. Remove the crankshaft pulley bolts.





b. Remove the hub bolt of the crankshaft pulley.
c.Remove the crankshaft pulley.
7. Crankshaft Pulley Hub Removal Procedure:
Tool Required: J 24420-B Crankshaft Pulley Hub Puller, or equivalent.
a. Remove the crankshaft pulley.





b. Position the J 24420-B onto the crankshaft pulley hub.





c. Turn the puller screw clockwise. This will remove the hub from the crankshaft.





8. Intake Manifold Removal:
a. Remove the throttle cable support bracket.





b. Remove the MAP sensor.
c. Remove the EGR valve.
d. Remove the upper intake manifold bolts.





e. Remove the upper intake manifold.





f. Remove the EGR injector.





g. Remove the fuel injector retainer bracket.





h. Disconnect the fuel pressure regulator from the lower intake manifold.





i. Remove the fuel injectors.





j. Disconnect the fuel pressure connection fitting.
k. Remove the lower intake manifold nuts.





l. Remove the lower intake manifold.





m. Remove the lower intake manifold gasket.
n. Clean the sealing surfaces on the upper and lower intake manifold and on the Cylinder head.





9. Valve Rocker Arm Cover Removal:
a. Remove the crankcase vent valve (PCV) and pipe assembly.





b. Remove the rocker arm cover bolts.
c. Remove the rocker arm cover.





d. Remove the rocker arm cover gasket.
10. EGR Valve Removal:
a. Remove EGR valve bolts.
b. Remove EGR valve and gasket.
c. Clean EGR valve base and sealing surface on the EGR adapter.
11. EGR Valve Adapter Removal:
a. Remove EGR valve. Refer to Powertrain Management.
b. Remove EGR valve adapter, bolts, and gasket.
^ Clean EGR adapter gasket surfaces.
^ Clean cylinder head sealing surface.
12. Valve Rocker Arm, Push Rod, and Stud Removal:
a. Remove the rocker arm nuts.

NOTE: Be sure that valve train components are kept together and identified so that they can be installed in their original location.

b. Remove the rocker arm balls.





c. Remove the rocker arms.





d. Remove the pushrods.





13. Cylinder Head Removal:
a. Remove the coolant pump.
b. Remove the thermostat housing.





c. Remove the engine lift bracket from the rear of the engine.





d. Remove the cylinder head bolts.





e. Remove the cylinder head stud-ended bolt.
f. Remove the cylinder head.





g. Clean the following areas:
^ Clean any carbon deposits from the combustion chambers.

CAUTION: Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad will damage the cylinder head and block surfaces. Abrasive pads also produce a fine grit that will contaminate the engine oil. It is only necessary to remove the gasket material. Do not attempt to remove all marks from the cylinder head gasket surfaces.

^ Clean all traces of the old cylinder head gasket from the cylinder head and from the engine block.
^ Clean the cylinder head bolt threads.
^ Clean the threads that are in the engine block.
h. Inspect the engine block to cylinder head mating surface for the following conditions:
^ Nicks
^ Heavy scratches
^ Any other damage





14. Valve Lifter Removal:
a. Remove the bolts that secure the lifter anti-rotation brackets.





b. Remove the anti-rotation brackets.





c. Remove the valve lifters from the lifter bore.
d. Inspect the valve lifter for the following conditions:
^ Lifter wear
^ Lifter scuffing
^ Loose roller shaft
e. Inspect the valve lifter bore in the engine block for wear and scuffing.
f. Inspect the roller for freedom of movement.
g. Inspect the roller surface for flat spots and pitting.
15. Oil Filter Adapter and Valve Assembly Removal:
a. Remove the oil filter.
b. Be sure that the gasket is removed with the filter.
c. Remove the oil filter adapter.
d. Remove the oil filter bypass valve using a screwdriver or punch to pry the valve out.
e. Clean the oil filter mounting surface.





16. Oil Pan Removal:
a. Remove the oil pan bolts.





b. Remove the oil pan nuts.





c. Remove the oil pan. Use a narrow putty knife in order to separate the oil pan from the engine block.





d. Remove the oil pan rear oil seal.
e. Clean the sealing surfaces of the oil pan and the engine block.





17. Oil Pump Drive Removal Procedure:
a. Remove the oil pump drive bolt.
b. Remove the oil pump drive. Do this by lifting and turning the oil pump drive.





18. Oil Pump Removal Procedure:
a. Remove the bolt that attaches the oil pump to the rear main bearing cap.





b. Remove the oil pump.





c. Remove the oil pump drive shaft.

CAUTION: Do not crack the oil pump drive shaft retainer.

d. Remove the oil pump drive shaft retainer.

NOTE: A loose oil pump tube can cause an air leak and a loss of oil pressure.





e. Inspect the oil pump pickup tube for looseness.





19. Engine Front Cover Removal:
a. Remove the engine front cover bolts.





b. Remove the engine front cover.
c. Remove the crankshaft front oil seal.





d. Clean the sealing surfaces on the engine block.





e. Clean the sealing surfaces on the engine front cover.





f. Clean the sealing surfaces on the front of the oil pan.
g. Remove any loose RTV.
h. Remove any pieces of the old RTV that interfere with installation.
i. Use a suitable solvent to clean oil from the following sealing surfaces:
^ The engine block sealing surface
^ The oil pan sealing surface
^ The engine front cover sealing surface
20. Timing Chain and Sprockets Removal:
Tool Required: J22888-20 Crankshaft Gear Puller, or equivalent.





a. Remove the timing chain tensioner bolts.





b. Remove the timing chain, the timing chain tensioner, and the camshaft sprocket at the same time.





c. Remove the crankshaft sprocket. Use the J 22888-20.





21. Camshaft Removal:
a. Remove the thrust plate bolts.





b. Remove the camshaft position sensor.

CAUTION: Do not damage the camshaft bearings while removing the camshaft.

c. Remove the camshaft.
22. Piston, Connecting Rod, and Bearing Removal:
Tool Required: J24270 Ridge Reamer, or equivalent.
a.Remove the piston
1. Turn the crankshaft until the piston is a bottom dead center.
2. Place a cloth on top of the piston.





3. Perform the cutting operation with the J 24270.
4. Turn the crankshaft until the piston is at top dead center.
5. Remove the cloth and cuttings.





b. Remove the connecting rod cap. Keep the connecting rod and the connecting rod cap together as mating parts.
1. Check the connecting rod and the connecting rod cap for identification marks.
2. Mark the parts if necessary to keep each connecting rod and cap together.





c. Remove the connecting rod bearings.
d. Remove the connecting rod and the piston.
1. Slide a piece of 3/8 fuel or vacuum hose over each connecting rod bolt. This protects the crankshaft journal during removal.
2. Push the piston out of the bore.
3. After removing the connecting rod and the connecting rod cap, assemble the connecting rod and the connecting rod cap. This helps keep the correct mating parts together.
e. For cleaning and inspection information, refer to Piston and Connecting rod Clean and Inspect.





23. Crankshaft Rear Oil Seal and Housing Removal:

CAUTION: Do not damage the crankshaft surface when prying out the crankshaft rear oil seal.

a. Remove the crankshaft rear oil seal. Pry the crankshaft rear oil seal out with a suitable pry tool.
b. Clean the crankshaft rear oil seal to engine block mating surface.
c. Inspect the following areas:
^ Inspect the seal bore for nicks
^ Inspect the seal bore for burrs
^ Inspect the seal mating surface on the crankshaft for nicks





24. Crankshaft, Bearings, and Bearing Cap Removal:
a. Remove the main bearing caps and remove the main bearings. Mark the main bearing caps in order to insure that they are installed in the same place from which they were removed.





b. Remove the crankshaft.
c. Clean the crankshaft. Clean any obstructions from the oil passages on the crankshaft.
d. Inspect the keyway and the threads in the front of the crankshaft and the threads in the flywheel bolt holes.
e. Inspect the bearing journals and inspect the thrust surfaces for the following items:
^ Wear
^ Cracks
^ Chips (Replace the crankshaft if the crankshaft is chipped)
^ Gouges (Replace the crankshaft if the crankshaft is gouged)
^ Roughness
^ Grooves
^ Discoloration due to overheating (Replace the crankshaft if the crankshaft is discolored)
e. Use a micrometer in order to measure the crankshaft taper. If the crankshaft taper is not within specifications, replace the crankshaft. Refer to Engine Mechanical Specifications.
f. Measure the crankshaft runout. If the crankshaft runout is not within specifications, replace the crankshaft. Refer to Engine Mechanical Specifications.
25. Cylinder Block Plug Removal:





a. Remove the cooling jacket plugs.
1. Use a suitable self-threading screw.
2. Drill a hole into the cooling jacket plug.
3. Install the self-threading screw.
4. Pry out the cooling jacket plug.





b. Remove the oil gallery screw plugs.
c. Remove the cooling jacket drain plugs.