Part 2

38. Remove the fuel injectors.
^ Remove and discard the O-ring seals.





39. NOTE: RH shown, LH similar.

Loosen the bolts and remove the valve covers.





40. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp and remove the thermostat housing.





41. Remove the bolt and the oil level indicator tube.





42. Remove the bolt and the knock sensor (KS).





43. Remove the nuts and the RH exhaust manifold and gasket.
^ Discard the nuts and the gasket.





44. Remove and discard the 6 RH exhaust manifold studs.
45. Remove the nuts and the LH exhaust manifold and gasket.
^ Discard the nuts and the gasket.





46. Remove and discard the 6 LH exhaust manifold studs.
47. Using the special tool to hold the crankshaft pulley, remove the bolt.





48. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.

Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley.
^ Discard the crankshaft pulley bolt.





49. Remove the bolts and the coolant pump pulley.





50. Remove the bolts and the coolant pump.





51. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the UP position.





52. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the special tool, remove the camshaft roller followers.





53. Remove the RH hydraulic chain tensioner.





54. Install the special tools on the RH cylinder head and tighten the top 2 clamp bolts.
^ Tighten to 10 Nm (89 inch lbs.).





55. CAUTION: The RH camshaft sprocket bolt is a LH-threaded bolt.

Remove the RH camshaft sprocket bolt.





56. Remove the bolt.





57. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





58. Remove the LH hydraulic chain tensioner.





59. Install the special tools on the LH cylinder head.





60. Remove the LH camshaft sprocket bolt.





61. Remove the bolt.





62. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





63. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the bolts in the sequence shown and remove the cylinder heads.
^ Discard the gaskets and the bolts.





64. 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 cylinder head gasket.

Clean and inspect the cylinder head sealing surfaces.
65. Using the special tool, remove the crankshaft front oil seal.





66. Remove the 5 cylinder block cradle-to-engine front cover bolts.
67. Remove the bolts and the engine front cover.





68. Remove the bolts and the oil pan.





69. Remove the bolt and the oil pump screen cover and tube.





70. NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.

Remove the cylinder block cradle inner bolts. Remove and discard the 2 washer seals.





71. Remove the cylinder block cradle Torx(R) bolts.





72. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.





73. Remove the oil pump pickup tube, the oil pump and the oil pump intermediate shaft.





74. Remove the oil filter adapter.





75. Inspect and install new O-ring seals, if necessary.





76. Remove the jackshaft rear plug.





77. Using the special tool, hold the crankshaft.





78. Remove the jackshaft sprocket rear bolt.





79. Remove the RH cassette bolt.





80. Remove the RH cassette.





81. Remove the oil pump bolt and retainer and then remove the oil pump drive.





82. Using the special tool to hold the crankshaft, loosen the front sprocket retaining bolt.





83. Remove the bolts and the chain tensioner.





84. Remove the chain guide.





85. Remove the bolt.





86. Remove the jackshaft and crankshaft sprockets and the chain.
^ Remove the crankshaft key.





87. Remove the bolt and the front cassette.





88. Remove the jackshaft thrust plate.





89. Remove the jackshaft.





90. Remove the balance shaft tensioner.
1 Install a pin in the balance shaft tensioner.
2 Remove the bolts.
3 Remove the balance shaft tensioner.





91. Remove the 2 bolts and the balance shaft chain guide.

92. NOTE: DO NOT remove the balance shaft sprocket bolt.

Remove the balance shaft chain and crankshaft sprocket.





93. Remove the balance shaft.
1 Remove the bolts.
2 Remove the balance shaft.





94. 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, following the manufacturer's instructions.

95. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.

Remove the connecting rod caps.
1 Remove the connecting rod cap.
2 Remove the connecting rod nuts.





96. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.





97. Remove the connecting rod bearings.





98. Remove the piston rings.





99. Clean and inspect the pistons.

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





101. NOTE: Number (or mark) the crankshaft bearing caps before removing them.

Remove the crankshaft main bearing caps.





102. Remove the crankshaft rear oil seal from the crankshaft.





103. Remove the crankshaft.





104. Remove the crankshaft main bearings and the thrust bearing.