Disassembly
NOTE: Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.1. Remove flywheel.
2. Remove exhaust manifolds.
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.
6. Disconnect ignition wires from the spark plugs.
NOTE: When removing an ignition wire from a spark plug, use Spark Plug Wire Remover 303-106 (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.
7. Remove EGR valve and EGR valve gasket if required.
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 303-009 (T58P-6316-D) and Vibration Damper Remover Adapter 303-176 (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.
12. Before attempting to remove the lower intake manifold, break the seal between the lower intake manifold and the cylinder block. 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.
CAUTION: Use care to prevent damage to machined surfaces or engine oil and coolant leakage Nay occur.
13. Remove rocker arms and push rods.
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.
14. Remove spark plugs.
15. Remove lower intake manifold and intake manifold gasket. Discard intake manifold gasket.
16. Remove cylinder heads. Discard cylinder head retaining bolts.
17. Remove and discard head gaskets.
18. Remove valve tappets.
NOTE:
- The location of each valve tappet should be identified. When the engine is assembled, each valve tappet should be installed in its original position.
- 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.
19. Remove oil bypass filter.
20. Remove oil pan and oil pan gasket. Discard oil pan gasket.
21. Remove oil pump.
22. Remove water pump and engine front cover as an assembly. Remove and discard engine front cover gasket.
NOTE: If necessary, the water pump can be removed from the engine front cover. Discard water pump housing gasket after removal.
23. Remove camshaft sprocket retaining bolt.
24. Remove camshaft sprocket, the crankshaft sprocket and the timing chain.
CAUTION: Use care to prevent damage to finished areas on the crankshaft or engine damage may occur.
NOTE: If the crankshaft sprocket is difficult to remove, it can be pried off using two large pry bars.
25. Remove camshaft thrust plate bolts and camshaft thrust plate from the end of the camshaft.
26. Remove camshaft. Use care to prevent damage to camshaft bearing surfaces.
27. If necessary, remove camshaft rear bearing cover from the back of the engine.
28. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using a Cylinder Ridge Reamer 303-016 (T64L-6011-EA). Before the ridge or deposits are removed, turn the crankshaft until the piston is at the bottom of its stroke. Cover the piston with a clean shop towel to collect the cuttings. 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.
CAUTION: Never cut into the ring travel area in excess of 0.794 mm (1/32 inch) or possible damage to engine may occur.
29. Remove connecting rod caps and pistons.
NOTE:
- The cylinder number is stamped on the top of the piston. Matched letters are stamped on the sides of corresponding connecting rod and cap.
- The location of each piston, connecting rod bearings and connecting rod cap should be noted. When the engine is assembled each component should be installed in its original position.
30. Remove crankshaft main bearing caps and crankshaft.
NOTE: The location of the crankshaft main bearings should be identified. When the engine is assembled, each crankshaft main bearing should be installed in its original position.
31. For cleaning purposes, oil gallery and cooling jacket plugs can be removed.