Disassemble

1. Engine Flywheel Removal:
a. Remove the flywheel bolts. Discard the bolts.
b. Remove the flywheel.
c. Inspect the flywheel for damage. If the flywheel is damaged, replace the flywheel.
d. Inspect the crankshaft and flywheel mating surfaces for burrs. If necessary, replace the flywheel.





2. Accessory Drive Belt Tensioner Removal:
a. Remove the drive belt tensioner bolts.
b. Remove the drive belt tensioner.





3. 0il Level Indicator and Tube Removal:
a. Remove the oil level indicator bolt.
b. Remove the oil level indicator.





4. Coolant Outlet Housing and Thermostat Removal:
a. Remove the housing bolts.
b. Remove the housing.





5. Water Pump Removal:
a. Remove the water pump pulley bolts.
b. Remove the water pump pulley.





c. Remove the water pump bolts.
d. Remove the water pump.





6. Intake Manifold Removal (Upper):
a. Remove the right spark plug wires. It the wires aside.
b. Remove the manifold vacuum source.
c. Remove the EGR outlet pipe from the intake manifold.
d. Remove the coolant outlet housing and thermostat.





NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

e. Remove the throttle body.





f. Remove the fuel rail.





g. Remove the upper intake manifold bolts.
h. Remove the upper intake manifold.

7. Intake Manifold Removal (Lower):





NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

a. Remove the upper intake manifold.
b. Remove the lower intake manifold bolts.
c. Remove the lower intake manifold.

8. Exhaust Manifold Removal (Left Side):
a. Disconnect the heated oxygen sensor electrical connector from the wire support bracket.
b. Remove the exhaust manifold heat shield nuts.
c. Remove the exhaust manifold heat shield.

CAUTION: When you remove the EGR tube from the left exhaust manifold, inspect the outlet pipe for leaks during installation. Replace the EGR adapter if the pipe leaks.





d. Remove the EGR outlet pipe from the exhaust manifold.





e. Remove the exhaust manifold studs.
f. Remove the exhaust manifold.

9. Exhaust Manifold Removal (Right Side):
a. Remove the heated oxygen sensor electrical connector from the lift bracket.
b. Remove the exhaust manifold heat shield nuts and shields.





c. Remove the exhaust manifold studs and bolts.
d. Remove the exhaust manifold.

10. Valve Rocker Arm Cover Removal (Right Side):
a. Remove the engine lift bracket.
b. Disconnect the right hand spark plug wires.
c. Remove the rocker arm cover bolts.
d. Remove the rocker arm cover.





11. Valve Rocker Arm Cover Removal (Left Side):
a. Remove the engine lift bracket.
b. Remove the ICM bracket.
c. Remove the rocker arm cover bolts.
d. Remove the rocker arm cover.

12. Valve Rocker Arm and Push Rod Removal:
a. Remove the rocker arm cover.





b. Remove the rocker arm bolts.
c. Remove the rocker arm.

13. Valve Lifter Removal:
a. Remove the valve guide retainer bolts.
b. Remove the retainer.





c. Remove the lifter guides.
d. Remove the valve lifters.

14. Cylinder Head Removal





a. Remove the cylinder head bolts.
b. Discard the cylinder head bolts.
c. Remove the cylinder head.
d. Remove the gasket.

15. Crankshaft Balancer Removal
a. Use the Flywheel Holding Tool in order to hold the flywheel.
b. Remove the balancer bolt.

CAUTION: Do not separate the pulley from the balancer. Service the pulley and the balancer as an assembly.





c. Use the Crankshaft Balancer Puller in order to remove the crankshaft balancer.
^ Invert the Crankshaft Balancer Puller so that the leg of the tool is facing away from the balancer.
^ Install the silver screws to the balancer.
^ Turn the Crankshaft Balancer Puller in order to remove the balancer from the crankshaft.
^ Remove the Crankshaft Balancer Puller from the balancer.

16. Engine Front Cover Removal:





a. Remove the sensor shield.





b. Remove the crankshaft position sensor.
c. Remove the bolts connecting the oil pan to the front cover.
d. Remove the front cover bolts.





e. Remove the front cover.





f. Remove the gasket.

17. Engine Front Cover Oil Seal Removal:

CAUTION: Do not damage the seal bore or the contact surfaces.





^ Use a screwdriver in order to pry out the oil seal.

18. Oil Filter Adapter and Valve Assembly Removal:
a. Remove the oil filter adapter bolts from the front cover.





b. Remove the following components:
^ The oil filter adapter
^ The gasket
^ The oil pressure valve
^ The spring

19. Oil Pump Removal:
a. Remove the front cover.
b. Remove the oil filter adapter.
c. Remove the pressure relief valve and spring.





d. Remove the oil pump cover screws.
e. Remove the oil pump cover.
f. Remove the gears.

20. Timing Chain and Sprockets Removal:





a. Align the timing marks on the sprockets. Position the timing marks as close together as possible.





b. Remove the timing chain damper.
c. Remove the camshaft sprocket bolt.
d. Remove the camshaft sprocket.
e. Remove the timing chain.
f. Remove the crankshaft sprocket.

21. Camshaft Removal:





a. Remove the camshaft thrust plate screws.
b. Remove the camshaft thrust plate.
c. Remove the camshaft.
^ Install three 5/16-18x4 inch bolts into the camshaft bolt hole.
^ Carefully rotate and pull the camshaft out of the camshaft bearings.

22. Camshaft Bearing Removal:
a. Remove the camshaft.
b. Remove the rear main oil seal housing.
c. Assemble the Camshaft Bearing Remover/Installer Set according to the manufacturer's recommendations.
d. Remove the camshaft bearings using the Camshaft Bearing Remover/Installer Set.

23. Balance Shaft Removal:





a. Remove the balance shaft drive gear bolt.
b. Remove the balance shaft drive gear.
c. Remove the balance shaft retainer bolts.
d. Remove the balance shaft retainer.
e. Remove the balance shaft gear.





f. Use the Slide Hammer in order to remove the balance shaft.





g. Use the Balance Shaft Remover in order to remove the rear bushing. It may take a considerable amount of force in order to loosen the bushing from the block bore.





24. Crankshaft Rear Main Oil Seal Removal:
^ Use a screwdriver in order to pry out the oil seal.

25. Crankshaft Rear Main Oil Seal Housing Removal
a. Remove the rear main oil seal housing bolts. The bolts may remain in the housing bolt holes.





b. Remove the rear main oil seal housing.

26. 0il Pan Removal:





a. Remove the oil level sensor.





b. Remove the oil pan bolts.
c. Remove the oil pan.
d. Remove the oil pan gasket.

27. 0il Pump Pipe and Screen Assembly Removal:





a. Remove the oil pump pipe screen bolts.
b. Remove the oil pump screen.
c. Remove the gasket.
d. Use solvent in order to clean the screen and the housing. Blow dry the screen and the housing.
e. Clean the gasket mating surfaces.

28. Piston, Connecting Rod, and Bearing Removal:
a. Mark the connecting rod cap and rod in order to reassemble the cap and rod properly.





b. Remove the connecting rod bolts.
c. Remove the connecting rod cap.
d. Install the Connecting Rod Assembly Guide to the connecting rod. Securely hand tighten the tool to the connecting rod.
e. Use hand pressure on the Connecting Rod Assembly Guide in order to push the connecting rod towards the top of the cylinder.

CAUTION: Remove any carbon or ridge at the top of the cylinder bore in order to avoid damaging the piston ring lands.





f. Remove the piston and the connecting rod from the top of the cylinder.
g. Remove the bearings.

29. Crankshaft, Bearings, and Bearing Cap Removal:





a. Remove the connecting rod caps.
b. Push the pistons and the connecting rods to the top of the cylinder bores.

NOTE: This engine has side bolts on all of the main caps except the rear cap. These bolts must be removed to service the caps.

c. Remove the side bolts.
d. Remove the main cap bolts.

CAUTION: Main bearing caps are press fit. Remove the caps carefully for service. Main Bearing Cap Puller has been designed to work with Slide Hammer in order to prevent damage to the bearing and cap. Main Bearing Cap Puller MUST be installed properly into the bolt holes of the caps and Slide Hammer attached to Main Bearing Cap Puller in order to properly remove the main cap without damaging the bearing or the cap. Any deviation from this procedure may cause damage to the cap and the bearing and may result in future engine damage.





e. Install the Main Bearing Cap Puller into the main cap bolt holes.
f. Tighten the bolts on the Main Bearing Cap Puller to 100 inch lbs.
g. Install the Slide Hammer to the Main Bearing Cap Puller.
h. Use the Slide Hammer in order to remove the main bearing cap.
i. Remove the crankshaft.