Disassembly

1. Remove engine.
2. Loosen four bolts retaining water pump pulley (8509) to water pump (8501) (do not remove bolts).
3. Release drive belt tensioner (6B209) and remove accessory drive belt (8620).
4. Remove water bypass tube to water thermostat housing hose at water bypass tube and remove hose and water thermostat housing assembly.
5. Remove engine control sensor wiring (12A581) from the A/C compressor (19703).
6. Remove bolts retaining A/C compressor to cylinder blocks (6010) and remove A/C compressor.
7. Disconnect main emission vacuum control connector (9E498) at all connections and remove main emission vacuum control connector.
8. Remove eight retaining nuts on RH and LH ignition wire covers and remove ignition wire covers.

CAUTION: Do not pull on ignition wires as the ignition wire may separate from the connector in the ignition wire boot.

9. Disconnect ignition wires from spark plugs (12405) with a gentle twist/pull motion on the ignition wire boot.
10. Disconnect all ignition wires from both ignition coils (12029).
11. Detach two center ignition wire separators (12297) from intake manifold studs.
12. Remove RH ignition wire and bracket (12280) and LH spark plug wire set (12281).
13. Disconnect generator wiring harness from generator (GEN)(10300) at B+ terminal and disconnect stator connector plug. Remove wiring harness retaining clip from generator mounting bracket (10153).
14. Remove bolts attaching generator mounting bracket to upper generator and intake manifold (9424). Remove generator mounting bracket.
15. Remove four loosened water pump pulley bolts and remove water pump pulley.
16. Disconnect power steering line from power steering pump (3A674).
17. Remove four bolts retaining power steering pump to engine front cover (6019) and cylinder blocks.
18. Disconnect engine control sensor wiring from engine coolant temperature sensor (ECT)(12A648) and at water bypass tube.
19. Remove two spacers and retaining nuts from water bypass tube hold-down braces to intake manifold studs and remove water bypass tube.
20. Remove two bolts retaining generator to cylinder blocks and remove generator.
21. Disconnect engine control sensor wiring from EGR backpressure transducer and IMRC actuator. Remove secondary air injection pump outlet hose (9B460) and secondary air injection manifold tube (9B449) from RH AIR diverter valve. Remove two bolts retaining EGR backpressure transducer and AIR diverter valve and bracket to rear of RH cylinder head (6049) and remove bracket.
22. Remove two bolts retaining heater water hose (18472) to rear of RH cylinder head and remove heater water hose.
23. Disconnect IMRC actuator control cables from the IMRC levers and brackets. Remove IMRC actuator.





24. Remove positive crankcase ventilation valve (PCV valve)(6A666) and crankcase ventilation tube (6758) assembly from RH valve cover (6582) and disconnect from throttle body (9E926). Remove crankcase vent connector and hose (6C324).
25. Disconnect engine control sensor wiring from camshaft position sensor (CMP)(6B288) oil pressure sensor (9278), crankshaft position sensor (CKP)(6C315), both ignition coils and both radio ignition interference capacitors (18801).
26. Disconnect engine control sensor wiring from knock sensor harness, RH heated oxygen sensor (HO2S)(9F472), throttle position sensor (TP)(9B989) or throttle position sensors (depending upon application), idle air control valve (IAC valve)(9F715), EGR vacuum regulator solenoid (9J459) and secondary air injection vacuum control.
27. Disconnect remaining retaining clips on engine control sensor wiring.
28. Disconnect fuel injectors and position engine control sensor wiring out of the way.
29. Remove secondary air injection pump outlet hose and secondary air injection manifold tube from LH AIR diverter valve.
30. Remove LH AIR diverter valve and bracket, ignition coils and bracket and secondary air injection vacuum control and bracket from the LH cylinder head.





31. Remove oil level indicator tube retaining bolt from LH cylinder head and remove oil level dipstick (6750) and oil level indicator tube (6754) from cylinder blocks.
32. Remove exhaust manifold retaining nuts and remove LH and RH exhaust manifold (9430). Discard exhaust manifold gaskets (9448).





33. Loosen and remove 20 bolts and studs retaining upper intake manifold to cylinder heads using removal sequence as follows:
34. Remove upper intake manifold and lower intake manifolds (IMRC) together.





35. Remove four fuel injection supply manifold bolts from upper intake manifold and remove fuel injection supply manifold (9F792) from fuel injectors.








36. Remove four bolts retaining RH and LH lower intake manifolds (IMRC) to upper intake manifold and remove lower intake manifolds (IMRC).

NOTE: Intake manifold upper gaskets (9H486) must be replaced when intake manifold retaining bolts have been loosened.

37. Remove intake manifold upper gasket and all load limiting spacers from RH and LH lower intake manifolds (IMRC) and discard.
38. Remove intake manifold gaskets (9439) from cylinder heads and discard.
39. Remove four bolts retaining water pump to cylinder blocks and remove water pump.
40. Remove bolt retaining belt idler pulley (8678) to engine front cover and slide belt idler pulley from engine front cover.
41. Remove crankshaft pulley retaining bolt and washer from crankshaft (6303).
42. Install Crankshaft Damper Remover T58P-6316-D on crankshaft pulley (6312) and remove crankshaft pulley.
43. Remove bolts and stud bolts retaining RH valve cover to cylinder head and remove RH valve cover.
44. Remove bolts and stud bolts retaining LH valve cover to cylinder head and remove LH valve cover.
45. Remove eight spark plugs.
46. Remove four bolts retaining oil pan (6675) to engine front cover.








47. Remove stud bolts and bolts retaining engine front cover to engine.
48. Remove harness from both knock sensors and remove wiring retainer clip from heater outlet hose. Remove harness.
49. Release heater hose outlet connection clamp at water bypass tube connector on cylinder blocks and remove heater outlet tube.

NOTE: Cylinder heads must not be set on head face with rocker arms (6564) installed. After rocker arms are removed, protect head face surface to avoid scratches and dents on cylinder head face sealing surfaces.

50. Remove rocker arms from intake valves (6507) and exhaust valves (6505) on cylinder heads. Follow proper procedures.

CYLINDER HEAD REMOVAL

51. Remove timing chains.
52. Rotate crankshaft counterclockwise 45° before top dead center (TDC). This will position all pistons (6108) below top of block deck face.





53. Using removal sequence, loosen and remove 10 cylinder head-to-cylinder-block retaining bolts on cylinder head to be removed. Repeat process on opposite side if both cylinder heads are to be removed. Remove cylinder heads.
54. Discard all cylinder head bolts removed.
55. Remove head gasket (6051) and discard.
56. If cylinder head is to be replaced and/or serviced, refer to Subassemblies, Cylinder Head.





57. Remove 12 oil pan retaining bolts. Remove oil pan and oil pan gasket (6710).
58. Remove three oil pump screen cover and tube retaining bolts. Remove oil pump screen cover and tube (6622) and O-ring.
59. Remove oil pump screen cover and tube spacer from main bearing cap stud.
60. Remove four oil pump retaining bolts and remove oil pump (6600).
61. Remove oil bypass filter (6714). If needed, remove oil pressure sensor prior to oil filter adapter removal.





62. Remove bolts retaining oil filter adapter (6881) to cylinder blocks. Remove oil filter adapter and oil filter adapter gasket (6840).

PISTON REMOVAL

63. Turn crankshaft until piston to be removed is at the high point of its travel.

NOTE: Pistons, connecting rods (6200) and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.

64. If more than one piston is being removed, identify the pistons, connecting rods and connecting rod caps for cylinder position.

NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA following manufacturer's instructions.





65. Remove the connecting rod cap and lower connecting rod bearing. Keep cap and lower connecting rod bearing together. Using Connecting Rod Guides T93P-6136-A inserted into the bottom of connecting rod bolt holes, push the piston, connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing and cylinder bore surfaces. Keep upper bearing and connecting rod together.

CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or possible engine damage may occur.

NOTE: Connecting rod bolts (6214) are retained in the bolt hole with a light press fit. The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod cap.

66. Using new connecting rod bolts, attach cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing (finger-tight) to prevent mixing parts and damaging the fractured joint face surfaces.

NOTE: Any piston rings that are removed from piston should be discarded and replaced with new rings.

67. If piston ring replacement is required, use a suitable piston ring expander to remove two compression rings. Remove two oil ring rails and expander by hand.

WARNING:COVER THE END OF THE PIN BORE WITH A HAND OR SHOP RAG WHEN REMOVING THE RETAINER RING SINCE IT HAS A TENDENCY TO SPRING OUT. EYE PROTECTION SHOULD BE WORN.

68. Using O-Ring Tool T71P-19703-C, remove the two piston pin retaining rings.
69. Gradually heat the piston to approximately 100°C (212°F).

NOTE: The piston and piston pin (6135) are a matched set. Keep pistons, piston pins, rings, connecting rods and connecting rod bearings together in proper cylinder order.

70. Using Piston Pin Tool D81L-6135-A or equivalent, press piston pin from piston and connecting rod.

CRANKSHAFT REMOVAL





71. Remove crankshaft rear oil seal and retainer (6K301).

NOTE: The location of the main bearing caps and the crankshaft main bearings (6333) should be identified. When the engine is assembled crankshaft main bearings which are to be reused should be installed in their original positions.





72. Remove 10 horizontal main cap side bolts from cylinder blocks to main bearing caps using removal sequence as shown. Save bolts for reinstallation.
73. With a 3/8-inch hex socket, loosen crankshaft main bearing cap adjusting screws (6C360) in the removal sequence as shown.
74. Loosen and remove 20 vertical bearing main cap retaining bolts in the removal sequence as shown and discard vertical bolts. These are torque-to-yield bolts and should not be reused.





75. Remove each main bearing cap and lower crankshaft main bearing. Keep each cap and lower crankshaft main bearing together.

CAUTION: When removing the crankshaft, use care not to damage any of the bearing surfaces on the crankshaft.

76. Remove crankshaft.
77. Remove No. 5 upper thrust bearing washer from rear of No. 5 cylinder block bulk head.
78. Remove and mark position of five upper crankshaft main bearings.
78. Check crankshaft main bearing clearance, if necessary.