Steps 51 - End

51. Disconnect the wiring harness retainers.





52. Disconnect the ground wire.
53. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.






54. NOTE: LH is shown, RH is similar.

Remove the bolts and all 8 ignition coils.





55. Remove the bolts and the thermostat housing.





56. Remove the 9 bolts and the intake manifold.





57. Remove the intake manifold gaskets.

58. 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 sealing surfaces.





59. Remove the bolt and the around wire.





60. Remove the heater hose if necessary.





61. Remove the bolts and the KS.





62. Remove the nut and the coolant tube.





63. Remove the bolts and the LH engine mount.





64. Remove the bolts and the RH engine mount.





65. Remove the RH cylinder block drain plug.
^ Reinstall the drain plug after draining the coolant.





66. Remove the LH cylinder block drain plug.
^ Reinstall the drain plug after draining the coolant.






67. 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.

NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.

Loosen the bolts and remove the LH valve cover.
^ Clean and inspect the mating surfaces and, if necessary, install new gaskets.






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.

NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.

Loosen the bolts and remove the RH valve cover.
^ Clean and inspect the mating surfaces and, if necessary, install new gaskets.

69. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

Remove the spark plugs.





70. Position the lobe of the camshaft upward.





71. Install the special tool between the valve spring coils to prevent valve stem seal damage.






72. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.

Using the special tool, compress the valve springs and remove the camshaft roller followers.





73. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.





74. Using the special tool, remove the crankshaft front oil seal.





75. Remove the 4 oil pan bolts.






76. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.

Remove the fasteners.





77. Remove the engine front cover from the cylinder block.





78. Remove the crankshaft sensor ring from the crankshaft.






79. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the timing chain tensioning system from both timing chains.
1 Remove the bolts.
2 Remove the timing chain tensioners.
3 Remove the timing chain tensioner arms.





80. Remove the LH and RH timing chains and the crankshaft sprocket.





81. Remove both timing chain guides.
^ Remove the bolts.
^ Remove both timing chain guides.





82. Install the special tool on both ends of the cylinder head.






83. 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 torque 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 that 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.

NOTE: RH is shown, LH is similar.

Remove the bolts and discard.
^ Remove the cylinder heads.





84. Remove and discard the cylinder head gaskets.

85. 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 that 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 the cylinder head 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 straining of the metal surfaces is normal.






86. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat within 0.010 mm (0.0004 inch) from end to end.

NOTE: LH is shown, RH is similar.

Support the cylinder head 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 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).
87. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent.





88. Remove the oil pan.
^ Remove the bolts.
^ Remove the oil pan.
^ Remove the oil pan Casket.





89. Remove the bolts and the oil pump screen cover and tube.





90. Remove the oil pump screen cover and tube spacer.





91. Remove the bolts and the oil pump.






92. 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 bolts and the connecting rod cap. Discard the bolts.






93. 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.





94. Remove the piston rings.
95. Clean and inspect the piston and connecting rods.






96. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

Remove the side bolts.





97. Remove and discard the bolts.





98. Remove the 5 main bearing caps and the lower crankshaft main bearings.





99. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.