Disassembly

DRAINING FLUIDS AND OIL FILTER REMOVAL





1. Remove the oil pan drain plug and allow the oil to drain.





2. Remove the oil filter.





3. Remove both engine block coolant drain plugs and allow the coolant to drain.

ENGINE FLYWHEEL REMOVAL
1. Remove the engine flywheel bolts.





2. Remove the automatic transmission engine flywheel (1) if applicable.
3. Remove the manual transmission engine flywheel (2) if applicable.

IMPORTANT: If replacing the manual transmission engine flywheel, NEW balance weights must be installed into the NEW flywheel in the same location as the old flywheel.





4. Note the position of any manual transmission engine flywheel balance weights for assembly (if applicable).

EXHAUST MANIFOLD REMOVAL (LEFT SIDE)
1. Remove the spark plug wires from the spark plugs.





2. Remove the EGR inlet pipe clamp bolt from the intake manifold.
3. Remove the EGR inlet pipe from the intake and exhaust manifolds.





4. Remove the exhaust manifold bolts and stud.
5. Remove the exhaust manifold heat shields.
6. Remove the exhaust manifold and gaskets.
7. Discard the gaskets.

EXHAUST MANIFOLD REMOVAL (RIGHT SIDE)





1. Remove the exhaust manifold bolts and heat shields.
2. Remove the exhaust manifold and gaskets.
3. Discard the gaskets.

WATER PUMP REMOVAL





1. Remove the coolant bypass hose and clamps.





2. Remove the water pump bolts.
3. Remove the water pump and gaskets.
4. Discard the gaskets.

CRANKSHAFT BALANCER REMOVAL

Tools Required
J 23523-F Crankshaft Hub Remover and Installer





1. Remove the crankshaft balancer bolt and washer.





2. Remove the crankshaft pulley bolts and pulley.





3. Use the J 23523-F in order to remove the crankshaft balancer.

NOTICE: Refer to Fastener Notice in Service Precautions.

3.1. Install the J23523-F plate and bolts.

Tighten
Tighten the J 23523-F bolts to 25 Nm (18 ft. lbs.).

3.2. Insert the J23523-F forcing screw.
3.3. Rotate the J 23523-F forcing screw clockwise to remove the crankshaft balancer.





4. Remove the crankshaft balancer.
5. Remove the J23523-F from the balancer.
6. Remove the balancer key (if required).





7. Note the position of any crankshaft balancer balance weights (if applicable).

VALVE ROCKER ARM COVER REMOVAL





1. Remove the PCV valve and tube.





2. Remove the valve rocker arm cover bolts and grommets.
3. Discard the grommets.





4. Remove the rocker arm cover.
5. Remove the gasket from the cover.
6. Discard the gasket.

DISTRIBUTOR REMOVAL
1. Remove the ignition coil wire from the coil.
2. Remove the distributor clamp and bolt.





3. Remove the distributor from the engine.

THROTTLE BODY REMOVAL





1. Remove the throttle body retaining studs.





2. Remove the throttle body.
3. Remove the throttle body gasket from the upper intake manifold.
4. Discard the gasket.

INTAKE MANIFOLD REMOVAL

IMPORTANT: The intake manifold may be removed as an assembly. Do not disassemble the individual manifold components unless service is required. Make sure the ends of the fuel system are properly sealed.

1. Remove oxygen sensor wire support bracket and nut.
2. Remove canister purge system tubing.





3. Remove the lower intake manifold bolts.
4. Remove the intake manifold assembly.
5. Remove and discard the gaskets.

VALVE ROCKER ARM AND PUSH ROD REMOVAL

IMPORTANT: Mark, sort, or organize the components for assembly.





1. Remove the following components from the cylinder head:
1.1. The valve rocker arm nuts
1.2. The valve rocker arm balls
1.3. The valve rocker arms





2. Remove the valve rocker arm stud.

IMPORTANT: Mark, sort, or organize the components for assembly.





3. Remove the valve pushrods.

CYLINDER HEAD REMOVAL
1. Remove the spark plugs.
2. Remove the spark plug wire supports and bolts.
3. Remove the coolant sensor (if applicable).





4. Remove the cylinder head bolts.

NOTICE: After removal, place the cylinder head on two wood blocks to prevent damage.





5. Remove the cylinder head.





6. Remove and discard the gasket.

VALVE LIFTER REMOVAL

Tools Required
J 3049-A Valve Lifter Remover (Plier Type)

IMPORTANT: Mark, sort, or organize components for assembly to original location.





1. Remove the valve lifter pushrod guide and bolts.





2. Remove the valve lifters.

IMPORTANT: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use the J 3049-A in order to remove these valve lifters.





3. Use the J 3049-A in order to remove the valve lifters.

OIL PAN REMOVAL





1. Remove the following fasteners from the oil pan:
- The bolts
- The nuts
2. Remove the oil pan and gasket.
3. Discard the gasket.

OIL PUMP REMOVAL





1. Remove the bolt that attaches the oil pump to the rear crankshaft bearing cap.





2. Remove the oil pump driveshaft and the retainer.
3. Separate the oil pump, driveshaft, and retainer.
4. Discard the retainer.

OIL LEVEL INDICATOR AND TUBE REMOVAL





1. Remove oil level indicator from the tube.
2. Remove the oil level indicator tube bracket bolt.
3. Remove the oil level indicator tube from the engine block.

ENGINE FRONT COVER REMOVAL





1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Discard the crankshaft position sensor O-ring seal.





4. Remove the engine front cover bolts and stud.

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

5. Remove the engine front cover.
6. Discard the engine front cover.

TIMING CHAIN AND SPROCKETS REMOVAL

Tools Required
J 5825-A Crankshaft Sprocket Puller





1. Remove the crankshaft position sensor reluctor ring.





2. Remove the camshaft sprocket bolts.
3. Remove the camshaft sprocket.
4. Remove the camshaft timing chain.





5. Remove the crankshaft sprocket using the J 5825-A.
6. Remove the crankshaft balancer key (if required).

BALANCE SHAFT REMOVAL

Tools Required
J 38834 Balance Shaft Service Kit





1. Remove the balance shaft drive gear.

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





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





3. Remove the bolts and the balance shaft retainer.

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





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





5. Use the J 38834 in order to remove the balance shaft rear bearing.

CAMSHAFT REMOVAL





1. Remove the camshaft retainer bolts and retainer.

NOTICE: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.





2. Remove the camshaft.
2.1. Install the three 5/16-18 x 4.0 inch bolts in the camshaft front bolt holes.
2.2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the bearings.

PISTON, CONNECTING ROD, AND BEARING REMOVAL

Tools Required
- J 5239 Connecting Rod Bolt Guide Set
- J 24270 Cylinder Ring Ridge Remover





1. Use the J 24270 in order to remove the cylinder ring ridge.
1.1. Turn the crankshaft until the piston is at the bottom of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 to remove all of the cylinder ring ridge.
1.4. Turn the crankshaft so the piston is at the top of the stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris.

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





2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.





4. 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.





5. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block.

CRANKSHAFT REAR OIL SEAL AND HOUSING REMOVAL





1. Remove the crankshaft rear oil seal housing nuts and bolts.
2. Remove the crankshaft rear oil seal housing and gasket.
3. Discard the gasket.





4. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing.
5. Discard the oil seal.
6. Remove the rear oil seal housing stud from the engine block.

CRANKSHAFT AND BEARINGS REMOVAL
1. Mark or identify the bearing cap locations and positions for assembly.





2. Remove the crankshaft bearing cap bolts.
3. Remove the crankshaft bearing caps.
4. Remove the crankshaft.
5. Remove the crankshaft bearings from the engine block.
6. Remove the crankshaft bearings from the crankshaft bearings caps.

OIL FILTER ADAPTER AND VALVE ASSEMBLY REMOVAL





1. Remove the oil filter adapter bolts.





2. Remove the oil filter adapter and gasket.
3. Discard the gasket.





4. Remove the oil filter adapter seal (if applicable).
5. Discard the oil filter adapter seal (if applicable).

ENGINE BLOCK PLUG REMOVAL





1. Remove the knock sensor from the rear of the engine block.





2. Remove the oil pressure sensor.





3. Remove the oil pressure sensor fitting.





4. Remove the coolant drain hole plugs from the engine block.





5. Remove the left side and rear oil gallery plugs.





6. Remove the front oil gallery plugs or balls.
Insert a rod into the rear oil gallery holes and drive out the plugs or balls.





7. Remove the oil filter bypass valve (if required).





8. Remove the camshaft rear bearing hole plug.
9. Remove the balance shaft rear bearing hole plug.
10. Remove engine block coolant core plugs (as required).

CAUTION: Wear safety glasses In order to avoid eye damage.

10.1. Drive a pointed punch into the center of the core plug.
10.2. Pry the plug from the engine block.
Remove all of the pieces of the damaged plug.
10.3. Clean the sides of the block core plug hole of all rust or debris.