Engine Disassembly

Refer to Figs. 14 and 29 when disassembling engine.

Fig. 14 Replacing Timing Chain (Part 1 Of 2):

Fig. 14 Replacing Timing Chain (Part 2 Of 2):

Fig. 29 Exploded View Of Cylinder Block:

PISTON, ROD & CRANKSHAFT

1. Remove engine as outlined under REMOVAL/INSTALLATION.
2. Remove cylinder head and timing chain as outlined under TIMING CHAIN.
3. Remove oil pan as outlined under OIL PAN.
4. Remove piston with connecting rods attached.
5. Remove rear oil seal retainer.

Fig. 30 Crankshaft Bearing Beam Bolt Removal Sequence:

6. Remove bearing beam bolts in sequence shown, Fig. 30. Bolts should be removed in two or three steps.

CYLINDER HEAD

1. Remove rocker arms, shims rocker arm guides and hydraulic lash adjusters. Keep components in order removed to be able to be installed in there original position.
2. Remove throttle chamber with accel-drum unit.
3. Remove EGR tube.

Fig. 31 Exhaust Manifold Bolt Removal Sequence:

4. Remove exhaust manifold cover and the exhaust manifold. Remove bolts in sequence shown in Fig. 31.
5. Remove fuel tube assembly as follows:
a. Release fuel system pressure as outlined under MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELEASE.
b. Disconnect injector harness connectors.
c. Disconnect vacuum hose from pressure regulator.
d. Disconnect fuel hoses from fuel tube assembly.
e. Remove injectors with fuel tube assembly.

Fig. 32 Intake Manifold Bolt Removal Sequence:

Fig. 33 Intake Manifold Collector Bolt Removal Sequence:

6. Remove intake manifold bolts and manifold in sequence shown, Fig. 32.
7. Remove intake manifold collector from intake manifold in sequence shown, Fig. 33.
8. Remove water outlet.
9. Remove water connector.
10. Remove thermostat housing with water pipe.
11. Remove valve components using suitable spring compression tool.
12. Remove valve oil seal.