Disassembly

Special Tools





1. Remove the bolts and the drive belt tensioner.





2. Remove the bolts and remove the generator mounting bracket.





3. Disconnect the TP sensor electrical connector.





4. Disconnect the Idle Air Control (IAC) bypass electrical connector.





5. Remove the EGR valve vacuum connector.





6. Disconnect the EGR backpressure transducer hoses.





7. Disconnect the upper EGR valve to exhaust manifold tube upper fitting.





8. If equipped with the DPFE system, disconnect the lower EGR valve to exhaust manifold tube lower fitting, and remove the EGR EGR valve to exhaust manifold tube.





9. Disconnect the following connections:
- The engine vacuum regulator (EVR) electrical connector.
- The engine vacuum regulator (EVR) vacuum connector.





10. If equipped with the Differential Pressure Feedback EGR (DPFE) system, disconnect the EGR backpressure transducer electrical connector.





11. Remove the screws and the intake cover plate.





12. To prevent distortion, remove the bolts in sequence shown.





13. Lift the intake manifold and disconnect the two vacuum connections and the two PCV heater hoses.
- Remove the intake manifold and discard the old gaskets.





14. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.





15. Remove the nut.





16. Disconnect the water heater tube from the lower intake manifold and remove the water heater tube nut and fitting.





17. Remove the upper radiator hose from the intake manifold.





18. Remove the water bypass hose.
1 Loosen the water bypass hose clamps.
2 Remove the water bypass hose.





19. Disconnect the eight fuel injector electrical connectors.
20. Remove the Camshaft Position Sensor (CMP sensor) and camshaft synchronizer.





21. To prevent distortion, remove the bolts in sequence.





22. Remove the lower intake manifold and discard the lower gasket.





23. Disconnect the oil pressure sensor electrical connector.





24. Disconnect the crankshaft position sensor electrical sensor and remove the fuel charging wiring.





25. Remove the bolts and the RH valve cover.





26. Remove the bolts and the LH valve cover.





27. Remove the bolts from each side.

NOTE:
- Mark the rocker arms to ensure that they will be reinstalled in their original positions.
- The RH is shown; the LH is similar.





28. Remove the eight rocker arm fulcrums from each side.





29. Remove the rocker arms and rocker arm fulcrum guides from each side.





30. Remove the RH and LH push rods.

NOTE: Mark the RH and LH push rods to ensure that they will be installed in their original positions.





31. Remove the bolts and remove the valve tappet guide plate retainer.





32. Remove the four valve tappet guide plates and the valve tappets using a valve tappet puller.

NOTE: Mark the valve tappets so they can be reinstalled in their original positions.





33. Remove the bolts in the indicated sequence and remove the cylinder head from each side.
- Discard the old bolts.





34. Remove the bolt and the O-ring.





35. Disconnect the water inlet hose from the oil cooler and remove the oil cooler.





36. Remove the bolts and the water pump pulley.





37. Remove the bolts and the water pump from the engine front cover.





38. Remove the bolt.

NOTE: Use a suitable strap wrench to hold the crankshaft pulley.





39. Use the Crankshaft Damper Remover to remove the crankshaft pulley.
1 Install the Crankshaft Damper Remover.
2 Remove the crankshaft pulley.

NOTE: The jackscrew from the Vibration Damper Remover Adapter must be added to the Crankshaft Damper Remover.





40. Remove the crankshaft position sensor (CKP sensor) and timing pointer.





41. Remove the bolts and remove the flywheel.





42. Remove the bolts and the oil pan.
- Discard the old oil pan gasket.





43. Use Front Cover Seal Remover to remove the crankshaft front seal.





44. Remove the bolts and studs and the engine front cover.
- Discard the old engine front cover gasket.





45. Remove the bolt.





46. Remove the camshaft sprocket, crankshaft sprocket and timing chain/belt at the same time.





47. Remove the bolts and the camshaft thrust plate.





48. Remove the camshaft from the cylinder block.





49. Remove the oil pump screen cover and tube.
1 Remove the nut.
2 Remove the bolts.





50. Remove the bolts and the oil pump.
51. Use a Cylinder Ridge Reamer to remove the ridge off the top of the eight cylinder bores.
52. Turn the crankshaft until the connecting rod cap being removed is in the down position.





53. Remove the sixteen nuts and the eight connecting rod caps.

NOTE: Mark the connecting rod caps so they can be reinstalled in the original positions.

54. Push the piston and connecting rod assembly out of the top of the cylinder.

CAUTION: Place rubber hose over the connecting rod studs to protect the crankshaft journals and cylinder walls from being damaged.





55. Remove the bolts and the five main bearing caps.





56. Remove the crankshaft from the cylinder block.
57. Remove the crankshaft rear oil seal from the crankshaft.
58. Remove the crankshaft main bearings from the cylinder block and main bearing caps.
59. Use Camshaft Bearing Set to remove the camshaft bearings from the cylinder block.