Part 2
Oil Pan Removal
1. Remove the engine oil level sensor (if applicable).
2. Remove the oil pan bolts and nuts.
3. Remove the oil pan.
4. Remove the oil pan gasket.
5. Discard the oil pan gasket.
Oil Pump Removal
1. Remove the oil pump bolt.
2. Remove the oil pump.
3. Inspect the pins (oil pump locator) for damage, and replace the pins if required.
1. Remove the crankshaft position sensor bolt
2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor seal (O-ring).
4. Discard the crankshaft position sensor seal (O-ring).
5. Remove the engine front cover bolts.
Important: After the composite engine front cover is removed do not reinstall the engine front cover. Always install a NEW engine front cover.
6. Remove the engine front cover.
7. Discard the engine front cover.
Timing Chain and Sprockets Removal
Tools Required
- J 5525-A Crankshaft Gear Remover
1. Remove the crankshaft position sensor reluctor ring.
Important: If the camshaft timing chain can be moved in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprocket is recommended during assembly.
2. Check the camshaft timing chain free play.
1. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2).
2. Measure the free play on the slack side (3) of the camshaft timing chain.
3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and the camshaft timing chain.
Caution: Wear safety glasses in order to avoid eye damage.
5. Remove the crankshaft sprocket using the J 5825-A.
6. Remove the crankshaft balancer key.
Balance Shaft Removal
Tools Required
- J 38834 Balance Shaft Service Kit
1. Remove the balance shaft drive gear.
Important: The balance shaft drive and balance shaft 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.
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 from the engine block.
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 or installing the camshaft to avoid damage to the camshaft bearings.
2. Remove the engine camshaft.
1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes.
2. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings.
3. Remove the bolts from the front of the engine camshaft.
Piston, Connecting Rod, and Bearing Removal
Tools Required
- J 5239 Connecting Rod Bolt Guide Set
- J 24270 Cylinder Bore Ridge Reamer
1. Use the J 24270 in order to remove the cylinder 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 the J 24270 to remove all of the 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.
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. 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.
5. Remove the connecting rod bearings.
- Keep the connecting rod bearings with the original connecting rod and connecting rod cap.
- Wipe the oil from the connecting rod bearings.
- Wipe the oil from the crankpins.
Crankshaft Rear Oil Seal and Housing Removal
1. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing.
Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing.
2. Discard the crankshaft rear oil seal.
3. Remove the crankshaft rear oil seal housing nut and bolts.
4. Remove the crankshaft rear oil seal housing.
5. Remove the crankshaft rear oil seal housing gasket.
6. Discard the crankshaft rear oil seal housing gasket.
7. Remove the crankshaft rear oil seal housing retainer stud from the engine block.
Crankshaft and Bearings Removal
1. Mark or identify the crankshaft 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 crankshaft bearing caps.
6. Remove the crankshaft bearing from the engine block.
Oil Filter Adapter Removal
1. Remove the oil filter adapter bolts.
2. Remove the oil filter adapter and the oil filter adapter gasket.
3. Discard the oil filter adapter gasket.
4. Remove the oil filter adapter seal (O-ring).
5. Discard the oil filter adapter seal (O-ring).
Engine Block Plug Removal
Tools Required
- J 41712 Oil Pressure Switch Socket
Caution: Wear safety glasses in order to avoid eye damage.
1. Remove the knock sensor from the engine block.
2. Remove the engine oil pressure gauge sensor using the J 41712.
3. Remove the engine oil pressure sensor fitting.
4. Remove the dowel straight pins (transmission locator) (if required).
5. Remove the engine block left side oil gallery plug.
6. Remove the engine block left rear oil gallery plug.
7. Remove the engine block right rear oil gallery plug.
8. Remove the expansion cup plug (camshaft rear bearing hole).
9. Remove the expansion cup plug (balance shaft rear bearing hole.
10. Remove the spring type S pin (crankshaft rear oil seal housing locator) if required.
11. Remove the front oil gallery plugs or balls from the front of the engine block.
12. Insert a rod into the rear oil gallery holes and drive out the plugs or balls.
13. Remove the oil filter bypass valve.