Disassembly
DRAINING FLUIDS AND OIL FILTER REMOVAL1. Remove the oil pan drain bolt and allow oil to drain from the oil pan.
2. Remove the oil filter.
3. Remove coolant jacket drain plugs and allow coolant to drain from the water jacket.
4. Install oil pan drain bolt and the coolant jacket plugs.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
- Oil Pan Drain Bolt to 45 Nm (33 ft. lbs.).
- Water Jacket Plugs to 15 Nm (11 ft. lbs.).
5. If cleaning or repairing engine block it is not necessary to reinstall the plugs.
ENGINE FLYWHEEL REMOVAL
1. Remove the flywheel bolts.
2. Remove the flywheel spacer if a flywheel spacer is used.
IMPORTANT: If the flywheel is cracked or damaged replace the flywheel.
3. Remove the flywheel.
OIL LEVEL INDICATOR AND TUBE REMOVAL
1. Remove the oil level indicator.
2. Remove the oil fill tube nut.
3. Remove the oil fill tube.
4. Remove the oil fill tube seal from the engine block.
EXHAUST MANIFOLD REMOVAL
1. Remove the Oxygen sensor from the exhaust manifold to prevent damage to the sensor.
2. Remove the exhaust manifold nuts.
3. Remove the exhaust manifold.
4. Remove the exhaust manifold gasket.
WATER PUMP REMOVAL
1. Remove the water pump drive pulley and bolts.
2. Remove the water pump attaching bolts.
3. Remove the water pump.
4. Remove the water pump gasket.
- Clean all sealing surfaces
- Inspect all sealing surfaces for burrs or imperfections
CRANKSHAFT BALANCER AND HUB REMOVAL
Tool Required
J 24420-B Crankshaft Pulley Hub Puller
1. Remove the crankshaft pulley bolts and crankshaft hub bolt.
2. Remove the crankshaft pulley.
3. Position the J 24420-B onto the crankshaft pulley hub.
4. Turn the puller screw clockwise.
5. Remove the hub from the crankshaft.
INTAKE MANIFOLD REMOVAL
1. Remove the throttle cable support bracket and throttle body.
2. Remove the throttle body.
3. Remove the EGR pipe to manifold bolts.
4. Remove the EGR pipe to EGR adapter bolt.
5. Remove the EGR pipe.
6. Remove the intake manifold bolts.
7. Remove the intake manifold nuts.
8. Remove the fuel rail bracket.
9. Remove the intake manifold.
VALVE ROCKER ARM COVER REMOVAL
1. Remove the water outlet adapter.
2. Remove the air cleaner resonator bracket.
3. Remove the rocker arm cover bolts.
4. Remove the rocker arm cover.
5. Remove the rocker arm cover gasket.
VALVE ROCKER ARM AND PUSH ROD REMOVAL
1. Remove the rocker arm bolts.
IMPORTANT: Be sure that valve train components are kept together and identified so that they can be installed in their original location.
2. Remove the rocker arms.
3. Remove the pushrods.
CYLINDER HEAD REMOVAL
1. Remove the EGR adapter.
2. Remove the engine accessory bracket.
3. Remove the engine lift bracket from the rear of the engine.
4. Remove the cylinder head bolts.
5. Remove the cylinder head.
6. Clean the following areas:
- Clean any carbon deposits from the combustion chambers.
- Clean all traces of the old cylinder head gasket from the cylinder head and from the engine block.
IMPORTANT: 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 the cylinder head bolt threads.
- Clean the threads that are in the engine block.
7. Inspect the engine block to cylinder head mating surface for the following conditions:
- Nicks
- Heavy scratches
- Any other damage
VALVE LIFTER REMOVAL
1. Remove the bolts that secure the lifter anti-rotation brackets.
2. Remove the anti-rotation brackets.
3. Remove the valve lifters from the lifter bore.
4. Inspect the valve lifter for the following conditions:
- Lifter wear
- Lifter scuffing
- Loose roller shaft
5. Inspect the valve lifter bore in the engine block for wear and scuffing.
6. Inspect the roller for freedom of movement.
7. Inspect the roller surface for flat spots and pitting.
OIL FILTER ADAPTER AND VALVE ASSEMBLY REMOVAL
1. Remove the oil filter.
2. Be sure that the gasket is removed with the filter.
3. Remove the oil filter adapter.
4. Remove the oil filter bypass valve using a screwdriver or punch to pry the valve out.
5. Clean the oil filter mounting surface.
OIL PAN REMOVAL
1. Remove the oil pan bolts.
2. Remove the oil pan nuts.
3. Remove the oil pan. Use a narrow putty knife in order to separate the oil pan from the engine block.
4. Remove the oil pan rear oil seal.
OIL PUMP REMOVAL
Oil Pump Drive Removal
1. Remove the oil pump drive bolt.
2. Remove the oil pump drive. Do this by lifting and turning the oil pump drive.
Oil Pump Removal
1. Remove the bolt that attaches the oil pump to the rear main bearing cap.
2. Remove the oil pump.
3. Remove the oil pump drive shaft.
IMPORTANT: Do not crack the oil pump drive shaft retainer.
4. Remove the oil pump drive shaft retainer.
IMPORTANT: A loose oil pump tube can cause an air leak and a loss of oil pressure.
5. Inspect the oil pump pickup tube for looseness.
ENGINE FRONT COVER REMOVAL
1. Remove the accessory drive belt tensioner.
2. Remove the water pump pulley.
3. Remove the engine front cover bolts.
4. Remove the engine front cover and gasket.
TIMING CHAIN AND SPROCKETS REMOVAL
Tool Required
J 22888-20 Crankshaft Gear Puller
IMPORTANT: Before removing the timing chain, measure the distance between the hole in the bracket and the unworn surface of the timing chain tensioner shoe.
If the distance between the hole and the unworn surface of the timing chain tensioner shoe is more than 8 mm (0.314 inch), replace the tensioner, timing chain, and both sprockets.
1. Remove the timing chain tensioner bolts.
NOTICE: Do not replace only the tensioner or the chain to correct a noise condition caused by the camshaft drive components. When replacing the tensioner or chain to correct a noise condition all of the camshaft drive components must be replaced.
2. Remove the timing chain, the timing chain tensioner, and the camshaft sprocket at the same time.
3. If removing camshaft, remove the camshaft position sensor.
4. Remove the crankshaft sprocket. Use the J 22888-20.
CAMSHAFT REMOVAL
1. Remove the camshaft thrust plate bolts.
2. Remove the camshaft position sensor.
IMPORTANT: Do not damage the camshaft bearings while removing the camshaft.
3. Remove the camshaft.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
Tool Required
J 24270 Ridge Reamer
1. Remove the piston.
1.1. Turn the crankshaft until the piston is a bottom dead center.
1.2. Place a cloth on top of the piston.
1.3. Perform the cutting operation with the J 24270.
1.4. Turn the crankshaft until the piston is at top dead center.
1.5. Remove the cloth and cuttings.
2. Remove the connecting rod cap. Keep the connecting rod and the connecting rod cap together as mating parts.
2.1. Check the connecting rod and the connecting rod cap for identification marks.
2.2. Mark the parts if necessary to keep each connecting rod and cap together.
3. Remove the connecting rod bearings.
4. Remove the connecting rod and the piston.
4.1. Slide a piece of 9.5 mm (0.375 inch) fuel or vacuum hose over each connecting rod bolt. This protects the crankshaft journal during removal.
4.2. Push the piston out of the bore.
4.3. After removing the connecting rod and the connecting rod cap, assemble the connecting rod and the connecting rod cap.
CRANKSHAFT REAR OIL SEAL REMOVAL
NOTICE: Do not damage the crankshaft surface when prying out the crankshaft rear oil seal.
1. Remove the crankshaft rear oil seal. Pry the crankshaft rear oil seal out with a suitable pry tool.
2. Clean the crankshaft rear oil seal to engine block mating surface.
3. 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
CRANKSHAFT AND BEARINGS REMOVAL
1. 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.
2. Remove the crankshaft.
3. Clean the crankshaft. Clean any obstructions from the oil passages on the crankshaft.
4. Inspect the keyway and the threads in the front of the crankshaft and the threads in the flywheel bolt holes.
5. 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)
6. 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.
7. Measure the crankshaft runout. If the crankshaft runout is not within specifications, replace the crankshaft. Refer to Engine Mechanical Specifications.
ENGINE BLOCK PLUG REMOVAL
1. Remove the cooling jacket core plugs.
1.1. Use a suitable self-threading screw.
1.2. Drill a hole into the cooling jacket plug.
1.3. Install the self-threading screw.
1.4. Pry out the cooling jacket plug.
2. Remove the cooling jacket drain plug.
3. Remove the right side oil passage plug.
4. Remove the oil pressure sender or switch assembly.
5. Remove the upper oil passage plug.
6. Remove the rear oil passage plugs.
7. Remove the camshaft rear cover and gasket.
8. Remove the engine front cover alignment pins.
9. Remove the front oil passage plug and discard.