Part 2

DISASSEMBLY (Steps 49-99)





49. Remove the 6 bolts, 8 stud bolts and the LH valve cover.
^ Remove and discard the gasket.





50. Remove the 9 bolts, 5 stud bolts and the RH valve cover.
^ Remove and discard the gasket.





51. Remove the 2 bolts and the thermostat housing.
^ Remove and discard the O-ring seal.





52. Remove the 4 bolts and the coolant pump.





53. Remove the 2 bolts and the coolant bypass tube.





54. Remove the bolt and the radio interference capacitor.





55. Remove the 15 bolts and the oil pan.
^ Remove and discard the gasket.





56. Remove the 2 bolts and the oil pump screen and pickup tube.
^ Remove and discard the O-ring seal.





57. Remove the 8 nuts and the oil pan baffle.





58. Remove the oil pressure sender.





59. If equipped, remove the block heater.





60. Use the special tool to hold the crankshaft damper and remove the bolt.





61. Using the special tool, remove the crankshaft damper.





62. Using the special tool, remove and discard the crankshaft front seal from the engine front cover.





63. Remove the bolt and the belt tensioner.





64. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Remove the stud bolt, 14 bolts and the front cover.
^ Remove and discard the gaskets.





65. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30 RFF" only (orange in color).

Remove the ignition pulse wheel.





66. Install the damper bolt.





67. NOTICE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

NOTE: LH shown, RH similar.

Remove the LH and RH spark plugs.





68. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number 1 cylinder at top dead center (TDC).
^ Verify that the camshafts are correctly located. If not, rotate the crankshaft 1 additional turn and recheck.





69. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.





70. Verify that the RH camshafts are in the neutral position.





71. Remove the RH timing chain tensioner arm.
1 Remove the 2 bolts.
2 Remove the tensioner.
3 Remove the tensioner arm.





72. Remove the 2 bolts, RH timing chain guide and the timing chain.





73. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.





74. Verify the LH camshafts are in the neutral position.





75. Remove the LH timing chain and tensioner arm.
1 Remove the 2 bolts.
2 Remove the tensioner.
3 Remove the tensioner arm.





76. Remove the LH timing chain and timing chain guide.





77. Remove the damper bolt and the crankshaft sprockets.





78. Remove the 3 bolts and camshaft oil seal retainer.
^ Remove and discard the press-in-place gasket.





79. Using a suitable press, remove the camshaft oil seal.





80. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.





81. NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.

NOTE: RH shown, LH similar.

NOTE: The camshaft caps have alignment dowels.

Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
^ Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.

82. Remove the LH and RH camshafts.





83. CAUTION: The camshaft roller followers must be installed in their original positions.

NOTE: RH shown, LH similar.

Remove the LH and RH camshaft roller followers.
^ Mark the location of the roller followers using a permanent-type marker.





84. NOTE: RH shown, LH similar.

Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
^ Remove and discard the gaskets and the bolts.

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 surface 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 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 staining of the metal surfaces is normal.

86. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.





87. Remove the 3 bolts and the power steering pump bracket.





88. Remove the 2 bolts and the oil separator cover.
^ Remove and discard the gasket.





89. Remove the crankshaft key.

90. 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 manufacturer's instructions

91. NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.





Remove the connecting rod cap bolts and cap.
^ Discard the connecting rod cap bolts.

92. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.





Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
^ Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.

93. Remove the engine block from the stand and place on a workbench.





94. Remove the bolts and studs in the indicated sequence.
^ Discard the lower cylinder block bolts.
^ Remove the lower cylinder block.





95. Remove the crankshaft rear main seal.
^ Remove the crankshaft.





96. Remove the crankshaft thrust bearing from the cylinder block.





97. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the bearings from the lower cylinder block.





98. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the crankshaft main bearings from the cylinder block.

99. Inspect the cylinder block, lower cylinder block, pistons and connecting rods.