Disassembly
CAUTION:Oil/Coolant leakage
Use care to prevent damage to machined surfaces or possible engine oil and coolant leakage may occur.
Component Locations
The location of each precision machined component should be noted. When engine is assembled each component should be installed in its original position. These components include:
- Rocker arms, push rods, rocker arm seats.
- Crankshaft main bearings and bearing caps.
- Connecting rod bearings and bearing caps.
- Pistons, piston rings and piston pins.
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
NOTE:
Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.
1. Remove flywheel. Refer to Transmission and Drivetrain.
2. Remove exhaust manifolds. Refer to Exhaust System.
3. Remove the oil filler cap and crankcase ventilation hose.
4. Remove positive crankcase ventilation valve (PCV valve).
5. Remove crankcase ventilation grommet and crankcase ventilation tube if necessary.
NOTE: When removing an ignition wire from a spark plug, use Spark Plug Wire Remover T74P-6666-A. Grasp and twist the boot back and forth on the plug insulator to free the boot. Use the tool to pull the boot from the plug. Do not pull on the ignition wire directly or it may become separated from the connector inside the boot.
6. Disconnect ignition wires from the spark plugs and remove spark plugs. Refer to Powertrain Management.
7. Remove EGR valve (EGR valve) and EGR valve gasket if so required. Refer to Exhaust System.
8. Remove the upper intake manifold and disconnect the engine control sensor wiring.
9. Remove crankshaft pulley and the crankshaft damper. Use Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B to remove vibration damper.
10. Remove camshaft position sensor housing hold-down clamp and the camshaft position sensor housing.
11. Remove valve covers.
CAUTION: The location of each rocker arm, push rod and rocker arm seat should be noted. When engine is assembled each component should be installed in its original position.
12. Remove rocker arms and push rods.
NOTE: Before attempting to remove the lower intake manifold, break the seal between the lower intake manifold and the cylinder block.
13. Wedge a large pry bar between the lower intake manifold and the cylinder block. Pry downward on the pry bar using the lug on the water pump as a leverage point.
14. Remove lower intake manifold and intake manifold gasket. Discard intake manifold gasket.
15. Remove cylinder heads. Discard cylinder head retaining bolts and head gaskets.
NOTE:
Valve Tappet Order/Location
The location of each valve tappet should be identified. When the engine is assembled, each valve tappet should be installed in its original position.
Valve Tappet Removal
If the valve tappets are stuck in the bores due to excessive varnish or gum deposits, it may be necessary to use a magnet, or claw-type tool to aid removal. When using a remover tool, rotate the valve tappet back and forth to loosen it from the gum or varnish that may have formed on the valve tappet.
16. Remove valve tappets.
17. Remove oil bypass filter.
18. Remove oil pan and oil pan gasket. Discard oil pan gasket.
19. Remove oil pump.
NOTE: If necessary, the water pump can be removed from the engine front cover. Discard water pump housing gasket after removal.
20. Remove water pump and engine front cover as an assembly. Remove and discard engine front cover gasket.
21. .Check timing chain freeplay. Replace components as require. Testing and Inspection
CAUTION: Use care to prevent damage to finished areas on the crankshaft or possible engine damage may occur.
22. Remove camshaft sprocket retaining bolt, camshaft sprocket, the crankshaft sprocket and the timing chain.
NOTE: If the crankshaft sprocket is difficult to remove, it can be pried off using two large pry bars.
23. Remove camshaft thrust plate bolts and camshaft thrust plate from the end of the camshaft.
24. Remove camshaft. Use care to prevent damage to camshaft bearing surfaces.
25. If necessary, remove camshaft rear bearing cover from the back of the engine.
CAUTION: NEVER cut into the ring travel area in excess of 0.794 mm (1/32 inch) or possible damage to engine may occur.
26. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder.
A. Turn the crankshaft until the piston is at the bottom of its stroke.
B. Cover the piston with a clean shop towel to collect the cuttings.
C. Remove the ridge and/or carbon deposits from each cylinder using a Cylinder Ridge Reamer T64L-6011-EA.
D. After the cutting operation, turn the crankshaft until the piston is at the top of its stroke and remove the shop towel with the cuttings.
NOTE: The location of each piston, connecting rod bearing and connecting rod cap, crankshaft main bearing and crankshaft main bearing cap should be noted. When the engine is assembled each component should be installed in its original position. The cylinder number is stamped on the top of the piston. Matched letters are stamped on the sides of corresponding connecting rod and cap. Main bearings should be numbered from front to rear.
27. Remove connecting rod caps and pistons.
28. Remove crankshaft main bearing caps and crankshaft.
29. For cleaning purposes, oil gallery and cooling jacket plugs can be removed.
30. Clean and inspect all components.