Part 2 of 2

Engine continued





36. Disconnect the hoses.





37. Remove the 3 bolts and the coolant pump.





38. Disconnect the hoses and remove the coolant tube.





39. Remove the nut, bolt and the coolant bypass tube.





40. Remove the stud bolt and the oil level indicator and tube
^ Remove and discard the O-ring seal.





41. Remove the bolts, studs and the oil pan.
^ Discard the gasket.





42. Remove the bolts, nut and the oil pump screen and pickup tube.





43. Remove and discard the O-ring seal.





44. Remove the nuts and the oil pan baffle.





45. Remove the oil pressure sender and, if equipped, the block heater.





46. Remove the bolt and the KS.





47. Use the special tool to hold the crankshaft damper and remove the bolt.





48. Using the special tool, remove the crankshaft damper.





49. Remove and discard the crankshaft front seal from the front cover.





50. Remove the bolt and the idler pulley.





51. Remove the bolt and the belt tensioner.





52. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Remove the bolts, studs and the front cover.
^ Discard the gaskets.





53. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" (orange in color).

Remove the ignition pulse wheel.





54. Install the damper bolt.






55. NOTE: LH shown, RH similar.

Remove the LH and RH spark plugs.





56. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).
^ Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.





57. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.





58. Verify that the RH camshafts are in the neutral position.





59. Remove the RH timing chain tensioner arm.
1. Remove the bolts.
2. Remove the tensioner.
3. Remove the tensioner arm.





60. Remove the bolts, RH timing chain guide and the timing chain.





61. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.





62. Verify the LH camshafts are in the neutral position.





63. Remove the LH timing chain and tensioner arm.
1. Remove the bolts.
2. Remove the tensioner.
3. Remove the tensioner arm.





64. Remove the LH timing chain and timing chain Guide.





65. Remove the damper bolt and the crankshaft sprockets.





66. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 inch) past flush of the end of the camshaft. The service pulley is pressed on flush to the end of the camshaft.

Using the special tools, remove the coolant pump drive pulley and discard.





67. CAUTION: To make sure of correct sealing, do not scratch the camshaft.

Using the special tools, remove the camshaft oil seal and discard.





68. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.





69. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.

NOTE: RH shown, LH similar.

NOTE: The camshaft caps have alignment dowels.

Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
^ Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
70. Remove the LH and RH camshafts.





71. CAUTION: The camshaft roller followers must be installed in their original positions.

NOTE: RH shown, LH similar.

Remove the LH and RH camshaft roller followers.
^ Mark the location of the roller followers, using a permanent-type marker.





72. NOTE: RH shown, LH similar.

Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
^ Discard the bolts and the gaskets.
73. Support the cylinder head on a bench with the head gasket side up.

74. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.

Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).





75. Remove the bolts and the oil separator cover.
^ Discard the gasket.





76. Remove the crankshaft key.