Disassemble

1. Draining Fluids and Oil Filter
a. Remove the oil pan drain plug and allow the oil to drain.
b. Remove the oil filter.
c. Remove both coolant drain plugs and allow the coolant to drain.





2. Engine Flywheel
a. Remove the engine flywheel bolts.
b. Remove the engine flywheel.





3. 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. Exhaust Manifold
a. Remove the studs and the bolts from the right exhaust manifold.
b. Remove the exhaust.
c. Remove the exhaust manifold gaskets.





5. Water Pump
a. Remove the mater pump bolts.
b. Remove the water pump and gaskets.





6. Crankshaft Balancer
^ Tools Required
- J 23523-F Crankshaft Hub Remover and Installer

a. Remove the crankshaft balancer bolt and washer.
b. Remove the crankshaft balancer.
c. Remove the crankshaft balancer hub bolt and washer.





d. Use the tool crankshaft hub remover in order to remove the crankshaft balancer hub.





7. Distributor
a. Remove the distributor clamp and bolt.
b. Remove the distributor.





8. Intake Manifold

NOTE: Make sure the ends of the fuel system are properly sealed.

a. Remove PCV valve and vacuum hose.
b. Remove EGR valve inlet tube from intake manifold.
c. Remove oxygen sensor wire support bracket and nut.
d. Remove canister purge system tubing.
e. Remove the lower intake manifold bolts.
f. Remove the lower intake manifold.





g. Remove the gaskets.





9. Valve Rocker Arm Cover
a. Remove the rocker arm cover bolts. Discard the grommets from the rocker arm valve cover.





b. Remove the rocker arm cover. Discard the old gasket.





10. Valve Rocker Arm and Push Rod
a. Remove the following components from the cylinder head
1) The valve rocker arm nuts.
2) The valve rocker arm balls.
3 The valve rocker arms.





b. Remove the valve rocker arm stud.





c. Remove the valve pushrods.
d. 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
11. 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 lifters cannot be removed with the valve lifter remover.





12. Cylinder Head
a. Remove the spark plugs.
b. Remove the cylinder head bolts.





c. Remove the cylinder head.





d. Remove the gasket.





13. Oil Filter Adapter and Valve Assembly
a. Remove the oil filter adapter bolts.





b. Remove the oil filter adapter, oil seal and gasket.





c. Remove the seal.





14. Oil Pan
a. Remove the following fasteners from the oil pan
^ The bolts
^ The nuts





b. Remove oil filter adapter bolts.
c. Remove oil filter adapter gasket.
d. Remove oil filter adapter O-ring seal, if equipped.

NOTE: Discard old oil pan gasket.

e. Remove the oil pan.





15. Oil Pump
a. Remove the bolt that attaches the oil pump to the rear crankshaft bearing cap.





b. Remove the oil pump drive shaft arid they d it retainer.





16. Engine Front Cover
a. Remove the crankshaft position sensor bolt.
b. Remove the crankshaft position sensor.





c. Remove the engine front cover bolts.

NOTE: Once the composite engine front cover is removed do not reinstall the cover. Always install a new engine front cover.

d. Remove the engine front cover.





17. Timing Chain and Sprockets
^ Tools Required
- J 5825 A Crankshaft Sprocket Puller, Or Equivalent

a. Remove the crankshaft position sensor reluctor ring.





b. Remove the crankshaft sprocket bolts.
c. Remove the camshaft sprocket.
d. Remove the timing chain.





e. Remove the crankshaft sprocket.
f. If necessary, remove the crankshaft sprocket key.





18. Balance Shaft
^ Tools Required
- J 38834 Balancer Shaft Bearing Service Kit, 0r Equivalent

a. Remove the camshaft sprocket bolts.
b. Remove the following items
1) Check camshaft timing chain free play. If the camshaft timing chain can be moved back and forth in excess of 16 mm (0.625 inch) replace the timing chain.
2) Remove the camshaft sprocket.
3) Remove the balance shaft drive gear.
c. Inspect the sprockets for chipped teeth and wear. Worn sprockets will wear a new chain.

NOTE: The balance shaft drive and driven gears are serviced as a set. The set includes the balance shaft driven gear bolt.

d. Remove the bolt and the balance shaft driven gear. Inspect the balance shaft drive and driven gears for nicks and burrs.





e. Remove the bolt and the balance shaft retainer.

NOTE: The balance shaft and the front bearing are serviced only as a package. Do not remove the front bearing from the balance shaft.





f. Use a soft faced hammer in order to remove the balance shaft and the front bearing.





g. Use the balancer shaft bearing service kit, and the in Order to remove the balance shaft rear bearing.





19. Camshaft
a. Remove the camshaft retainer bolts and retainer.





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. 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.
b. Remove the connecting rod nuts.
c. Remove the connecting rod cap.

NOTE: Place matchmarks or numbers on the connecting rods and the connecting rod caps. Assemble the connecting rod caps to the matching connecting rods.

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. 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. Insert a screw driver into the notches provided in the rear seal retainer and pry out the seal.





22. Crankshaft, Bearings, and Bearing Cap
a. Remove the crankshaft bearing cap bolts.
b. Remove the crankshaft bearing caps.
c. Remove the crankshaft.
d. Remove the crankshaft bearings from the bearing caps and from the engine block.