Removal

1. Remove engine under cover.
2. Drain engine oil.
3. Remove front differential and drive shafts assembly.
4. Remove drive belt for generator, fan with fluid coupling and water pump pulley.
5. Remove cylinder head assembly.
6. w/ A/C: Disconnect A/C compressor and bracket.





(a) Remove the 4 bolts, and disconnect the compressor from the bracket.

NOTE: Put aside the compressor, and suspend it.





(b) Remove the 4 bolts and A/C compressor bracket.
7. Remove generator, adjusting bar and bracket.
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and wire clip.





(c) Remove the lock, pivot bolts and the generator.
(d) Remove the bolt and adjusting bar.





(e) Remove the 3 bolts and generator bracket.
8. Remove crankshaft position sensor.





(a) Remove the 2 bolts and crankshaft position sensor.
(b) Remove the O-ring from the crankshaft position sensor.
9. Remove flywheel housing under cover and dust seal.
10. Remove oil pan.
(a) Remove the 16 bolts and 2 nuts.





(b) Insert the blade of Special Service Tool (SST) Oil Pan Seal Cutter # 09032 - 00100 or equivalent between the cylinder block and oil pan, cut off applied sealer and remove the oil pan.

CAUTION: Be careful not to damage the oil pan flanges of the oil pan and cylinder block.





11. Remove oil strainer.
Remove the bolt, 2 nuts, oil strainer and gasket.
12. Remove crankshaft pulley.
(a) w/ A/C: Remove the 4 bolts, No. 2 and No. 3 crankshaft pulleys.





(b) Using SST Crankshaft Pulley Holding Tool # 09213 - 54015, and Companion Flange Holding Tool # 09330 - 00021 or equivalents, remove the pulley bolt.
(c) Remove the crankshaft pulley.





NOTE: If necessary, remove the pulley with SST Puller C Set # 09950 - 50010 (Hanger 150 # 09951 - 05010, Slide Arm # 09952 - 05010, Center Bolt 100 # O9953 - 05010, Claw No. 2 # 09954 - 05020) or equivalents and crankshaft pulley bolt.

13. Remove timing chain cover.





(a) Remove the 2 water bypass pipe nuts.
(b) Remove the 2 timing chain cover bolts.





(c) Remove the 9 bolts and 2 nuts.
(d) Using a plastic faced hammer, loosen the chain cover and remove the timing chain cover and 3 gasket.





14. Remove No. 1 timing chain and camshaft timing gear.





15. Remove crankshaft timing gear.

NOTE: If necessary, remove the gear with SST Puller B Set # O9950 - 40010 (Hanger 150 # 09951 - 04010, slide Arm # 09952 - 04010, Center Bolt 100 # 09953 - 04010, Arm 25 # 09954 - 0401O, Claw No. 6 # O9955 - 04060) or equivalents and crankshaft pulley bolt.





16. Remove No. 1 timing chain tensioner slipper and No. 1 vibration damper.
(a) Remove the bolt and slipper.
(b) Remove the bolt, nut and No. 1 damper.
17. Remove No. 2, No. 3 vibration dampers and No. 2 chain tensioner.





(a) Install a pin to the No. 2 chain tensioner and lock the plunger.





(b) Remove the bolt and No. 2 damper.
(c) Remove the 2 bolts and No. 3 damper.
(d) Remove the nut and No. 2 chain tensioner.





18. Remove balance shaft drive gear, shaft, No. 2 timing chain and No. 2 crankshaft timing sprocket.
(a) Remove the bolt from the balance shaft drive gear.
(b) Remove the balance shaft drive gear with the shaft.
(c) Remove the No. 2 timing chain with the No. 2 crankshaft timing sprocket.





19. Remove No. 4 vibration damper.
Remove the 2 bolts and No. 4 damper.