Disassembly
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Special Tool(s)
Disassembly
1. Illustration 1 of 19. Remove the components in the order indicated.
2. Mount the engine on a suitable engine stand.
3. Illustration 2 of 19. Remove the components in the order indicated.
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4. Illustration 3 of 19. Remove the components in the order indicated.
5. Illustration 4 of 19. Remove the components in the order indicated.
6. Illustration 5 of 19. Remove the components in the order indicated.
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7. Illustration 6 of 19. Remove the components in the order indicated.
8. Illustration 7 of 19. Remove the components in the order indicated.
9. Illustration 8 of 19. Remove the components in the order indicated.
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10. Illustration 9 of 19. Remove the components in the order indicated.
11. Illustration 10 of 19. Remove the components in the order indicated.
12. Illustration 11 of 19. Remove the components in the order indicated.
13. Illustration 12 of 19. Remove the components in the order indicated.
14. Clean and inspect the exhaust manifolds.
15. Illustration 13 of 19. Remove the components in the order indicated.
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16. Illustration 14 of 19. Remove the components in the order indicated.
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17. Illustration 15 of 19. Remove the components in the order indicated.
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18. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed, is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Illustration 16 of 19. Remove the components in the order indicated.
19. Illustration 17 of 19. Remove the components in the order indicated.
20. Illustration 18 of 19. Remove the components in the order indicated.
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21. Illustration 19 of 19. Remove the components in the order indicated.
Item 4: Crankshaft Rear Oil Slinger Disassembly Note
1. Using the special tools, remove the crankshaft oil slinger.
Item 5: Crankshaft Rear Oil Seal Disassembly Note
1. Using the special tools, remove the crankshaft rear seal.
Item 8: Crankshaft Rear Oil Seal Retainer Plate Disassembly Note
1. After retainer plate removal, mount the engine on an engine stand.
Items 19 and 20: Engine Lifting Bracket and Bolts Disassembly Note
1. Remove the right side bolts and bracket (not shown).
Item 37: Crankshaft Pulley Disassembly Note
1. Using the special tool, remove the crankshaft vibration damper.
Item 38: Crankshaft Front Seal Disassembly Note
1. Using the special tool, remove the crankshaft front seal.
Item 44: Generator Support Bracket Disassembly Note
1. Disconnect the generator electrical connectors.
2. Remove the bolt and position aside the radio interference capacitor.
3. Disconnect the wiring harness retainers.
4. Remove the upper radiator hose bracket and the radio capacitor.
Item 47: Oil Filter Disassembly Note
1. Disconnect the oil pressure switch electrical connector.
2. Remove the power steering hose support bracket.
Item 49: Power Steering Pump Pulley Disassembly Note
1. Using the special tool, remove the power steering pump pulley.
Item 50: Power Steering Pressure Hose Disassembly Note
1. Drain the power steering pump fluid into a suitable container.
Item 56: Vacuum Harness Disassembly Note
1. Disconnect the brake booster vacuum hose.
2. Disconnect the vacuum hoses from the throttle body adapter and the fuel pressure regulator.
3. Disconnect the vacuum hoses from the EGR valve and the EVAP canister purge solenoid.
4. Remove the vacuum hose harness.
Item 57: Engine Wiring Harness Disassembly Note
1. Remove the bolt and the ground wire.
2. Disconnect the eight fuel injector and ignition coil electrical connectors.
3. Disconnect the CKP sensor electrical connector.
4. Disconnect the A/C compressor electrical connector.
5. Disconnect the Camshaft Position (CMP) sensor electrical connector.
6. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
7. Disconnect the Knock Sensor (KS) electrical connector and the wiring harness pin - type retainer.
8. Disconnect the Throttle Position (TP) sensor and the idle air control (IAC) valve electrical connectors.
9. Disconnect the EGR vacuum regulator solenoid electrical connector.
10. Remove the engine wiring harness.
Item 76: Intake Manifold Disassembly Note
1. 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.
Clean the intake manifold sealing surfaces.
Item 102: RH Engine Support Insulator Bracket Disassembly Note
1. Remove the bolt and the transmission bracket.
2. NOTE: LH shown; RH similar.
Remove the RH and LH cylinder block drain plugs.
^ Reinstall the plugs after draining the coolant.
Items 105 and 109: RH and LH Valve Cover Disassembly Note
NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
1. Loosen the bolts and remove the left valve cover.
^ Clean and inspect the mating surfaces, and if necessary, install new gaskets.
2. Loosen the bolts and remove the right valve cover.
^ Clean and inspect the mating surfaces, and if necessary, install new gaskets.
3. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Remove the spark plugs.
Item 121: Engine Front Cover Disassembly Note
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1. Remove the engine front cover fasteners in the sequence shown.
Item 125: Camshaft Roller Followers Disassembly Note
NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
1. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
2. Using the special tool, compress the valve spring and remove the roller follower.
3. Repeat the above steps to remove all the roller followers.
Item 149: Oil Pump Disassembly Note
1. Remove the bolts and the oil pump screen cover and tube.
2. Remove the oil pump screen cover and tube . spacer.
Items 150 - 155: RH and LH Cylinder Head Bolts, Cylinder Heads and Gaskets Disassembly Note
1. Install the Lifting Handles on both ends of the cylinder head.
2. CAUTION: Cylinder head bolts must be discarded and new bolts installed. They are tighten - to - yield designed and cannot be reused.
CAUTION: Place cylinder head on cardboard or wood surface to prevent damage to the joint face.
NOTE: RH is shown LH is similar.
Remove the bolts and discard.
^ Remove the cylinder heads.
3. Discard the head gasket.
4. 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.
Clean and inspect the sealing surfaces.
Item 157: Connecting Rod Caps Disassembly Note
1. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connector rods and rod caps for correct orientation.
Install the connecting rod caps in their correct locations.
Item 160: Piston and Connecting Rod Disassembly Note
1. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer Follow the manufacturer instructions
2. CAUTION: Do not scratch the cylinder walls or crankshaft journal with the connecting rod.
Use the Connecting Rod Installer to push the piston through the top of the cylinder block.