Part 2
EngineDisassembly (Steps 39-77)
39. Remove the 7 studs and 3 bolts and the RH valve cover. Discard the gasket.
^ Clean the mating surface.
40. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Remove the 8 spark plugs.
41. Position the lobe of the camshaft up.
42. Install the special tool between the valve spring coils to prevent valve stem seal damage.
43. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
Use the special tool to compress the valve springs and remove the 16 camshaft roller followers.
44. Remove the bolt and the accessory drive belt idler pulley.
45. Remove the 4 bolts and the coolant pump pulley.
46. Remove the 4 bolts and the coolant pump.
47. Remove the crankshaft pulley bolt.
48. Use the special tool to remove the crankshaft pulley.
49. Use the special tool to remove the crankshaft front seal.
50. Remove the 16 bolts and the oil pan.
^ Discard the gasket
51. Remove the 3 bolts, the oil pump screen and pickup tube.
52. Remove the oil pump screen and pickup tube spacer.
53. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
Remove the 15 fasteners in the sequence shown.
54. Remove the engine front cover from the cylinder block.
55. Remove the crankshaft sensor ring from the crankshaft.
56. Position the crankshaft with the keyway at the 12 o'clock position.
57. Remove the timing chain tensioning system from both timing chains.
1 Remove the 4 bolts.
2 Remove the timing chain tensioners.
3 Remove the timing chain tensioner arms.
58. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Remove the LH and RH timing chains and the crankshaft sprocket.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Repeat for the LH timing chain and crankshaft sprocket.
59. Remove both timing chain guides.
1 Remove the 4 bolts.
2 Remove the LH timing chain guide.
3 Remove the bolts.
4 Remove the RH timing chain guide.
60. Remove the RH exhaust manifold.
1 Remove the 8 nuts.
2 Remove the RH exhaust manifold.
3 Remove the RH exhaust manifold gasket and discard.
61. Remove the LH exhaust manifold.
1 Remove the 8 nuts.
2 Remove the LH exhaust manifold.
3 Remove the LH exhaust manifold gaskets and discard.
62. Remove the bolt and the oil level indicator tube.
63. Clean and inspect the exhaust manifolds.
64. Install the special tool on both ends of the cylinder head.
65. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Remove the 16 hydraulic lash adjusters.
66. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the 10 bolts and the RH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
67. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the 10 bolts and the LH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
68. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both cylinder heads and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3 Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4 Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
69. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.
Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 inch) across at 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).
70. Remove the 4 bolts and the oil filter adapter.
^ Discard the gasket.
71. Remove the 3 oil pump bolts and the oil pump.
72. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an cylinder ridge reamer, following the manufacturer instructions.
73. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
Remove the 2 bolts and the connecting rod cap.
^ Discard the bolts.
74. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Use the special tool to push the piston through the top of the cylinder block.
75. CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
Remove the crankshaft bearing cap fasteners.
1 Remove and discard the 10 cross-mounted main cap bolts.
2 Loosen the 10 jack screws.
3 Remove and discard the 10 main cap bolts.
76. Remove the 5 main bearing caps and the lower crankshaft main bearings.
77. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.