Disassembly
SPECIAL TOOLS REQUIREDTools and Equipment
1. Remove ignition wires and spark plugs.
NOTE: This procedure will disassemble and assemble a complete engine with the engine removed from the vehicle.
Part 1 Of 2:
Part 2 Of 2:
2. Remove oil bypass filter and oil filter adapter.
Gasoline Engine:
3. Disconnect fuel charging wiring from electronic engine controls, fuel injectors and ignition coils and remove fuel charging wiring.
4. Remove six flywheel retaining bolts and remove flywheel from crankshaft.
5. Remove crankcase vent connector and hose assembly, main emission vacuum control connector and air bypass valve inlet tube.
6. Remove generator mounting bracket and two bolts retaining generator to cylinder block.
7. Remove water pump pulley.
8. Remove A/C compressor.
9. Remove drive belt idler pulley and ignition coil mounting brackets with ignition coils.
10. Disconnect EGR transducer hoses from EGR valve to exhaust manifold tube.
11. Disconnect EGR valve to exhaust manifold tube from EGR valve tube to manifold connector.
12. Remove RH and LH exhaust manifolds.
13. Remove water hose connection, water thermostat and O-ring.
14. Remove EGR valve heat shield.
15. Remove EGR valve to exhaust manifold tube.
16. Remove throttle body adapter.
17. Remove accelerator cable bracket retaining nut.
18. Remove nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
19. If necessary disassemble intake manifold.
a. Remove engine coolant temperature sensor (ECT sensor) and water temperature indicator sender unit.
b. Remove four bolts retaining fuel injection supply manifold and remove fuel injection supply manifold and fuel injectors.
20. Remove RH and LH valve covers.
21. Remove crankshaft pulley bolt and crankshaft pulley retaining washer.
22. Using Crankshaft Damper Remover 303-009, pull crankshaft pulley from crankshaft.
23. Remove crankshaft position sensor (CKP sensor) and camshaft position sensor (CMP sensor) from engine front cover.
24. Remove oil pan and oil pan gasket.
25. Remove EGR transducer assembly.
26. Remove heater water hose.
27. Remove water pump.
28. Remove engine front cover.
29. Position crankshaft on top dead center (TDC) No. 1 cylinder.
30. Remove timing chains.
31. Rotate crankshaft counterclockwise 45 degrees.
NOTE: This will position all pistons below top of cylinder block deck face.
32. Remove RH and LH cylinder heads. Discard all head bolts.
33. Remove and discard head gaskets.
34. If cylinder heads are to be serviced.
35. Remove oil pump and oil pump screen cover and tube.
36. Remove crankshaft oil slinger and crankshaft rear oil seal using Rear Crankshaft Slinger Remover, Rear Crankshaft Seal Remover and Slide Hammer.
37. Remove crankshaft rear oil seal retainer.
38. Turn crankshaft until piston to be removed is at the high point of its travel. If more than one piston is being removed, identify the pistons, connecting rods and connecting rod caps for cylinder position.
NOTE: Pistons, connecting rods and connecting rod bearings should be numbered to make sure they are assembled in their original positions.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA.
39. Remove the connecting rod cap and lower connecting rod bearing. Keep cap and lower connecting rod bearing together. Push the piston, connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the bearing and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.
40. Using new connecting rod bolts, attach connecting rod cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the fractured joint face surfaces.
CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or possible engine damage may occur.
NOTE: Connecting rod bolts are retained in the connecting rod cap with a light press fit. The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod cap.
41. If piston ring replacement is required, use a suitable piston ring expander. Remove two compression rings. Remove two oil ring rails and expander by hand.
NOTE: Any piston rings that are removed from piston should be discarded and replaced with new piston rings.
42. Mark connecting rod cap to make sure reassembly with same piston and installation in same cylinders from which they were removed.
43. For piston service Disassembly And Assembly
44. Remove horizontal main cap side bolts from cylinder block.
45. Loosen crankshaft main bearing cap adjusting screws on main bearing caps.
46. Remove bearing main cap retaining bolts. These are torque-to-yield bolts and should not be reused.
47. Remove each main bearing cap and lower crankshaft main bearing and crankshaft thrust main bearing. Keep each cap, lower crankshaft main bearing and crankshaft thrust main bearing together.
NOTE: The location of the main bearing caps and the main bearing inserts should identified. When the engine is assembled and bearings are to be reused, they should be installed in their original positions.
48. Remove crankshaft.
CAUTION: When removing the crankshaft, use care not to damage any of the bearing surfaces on the crankshaft.
49. Clean and inspect crankshaft and cylinder block. Replace worn or damaged components as required.