Disassembly
CAUTION:Component Location/Orientation
The location and orientation of each precision machined component should be noted. When engine is assembled each component should be installed in its original position. These components include:
- Rocker arms, rocker arm seats, push rods and valve tappets.
- Connecting rod, connecting rod bearings and bearing caps.
- Crankshaft main bearings and bearing caps.
- Pistons, piston rings and piston pins.
- Camshafts and camshaft journals.
NOTE: Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.
1. Remove flywheel (6375) and rear engine plate (7007). Refer to Transmission and Drivetrain.
2. Remove upper intake manifold (9424).
NOTE: When LH exhaust manifold (9430) is removed, note location of oil level indicator tube support bracket.
3. Remove LH and RH exhaust manifolds. Refer to Exhaust System.
4. Refer to Powertrain Management and remove the following emissions components:
- Disconnect front evaporative emission hose.
- Front and rear crankcase ventilation tube (6758).
- Positive crankcase ventilation valve (PCV)(6A666).
5. Disconnect water bypass tube (8548) and water bypass hose (8597) at lower intake manifold. Remove heater water outlet tube retaining bolts and heater water outlet tube (18663) from water pump (8501). Refer to Cooling System.
NOTE: When removing an ignition wire from a spark plug (12405), use Spark Plug Wire Remover T74P-6666-A. Grasp and twist boot back and forth on spark plug insulator to free boot. Use tool to pull boot from spark plug. Do not pull on ignition wire directly or it may become separated from connector inside boot.
6. Disconnect ignition wires from spark plugs.
7. Remove the following components:
- Throttle body (9E926) and throttle body gasket (TB gasket)(9E936).
- EGR valve (EGR valve)(9D475).
- Upper intake manifold and intake manifold upper gasket (9H486).
- Fuel injectors and fuel injection supply manifold (9F792).
NOTE:
Crankshaft Pulley And Vibration Damper Separation
If the crankshaft pulley and vibration damper have to be separated, mark the damper and pulley so that they may be reassembled in the same relative position. This is important as the damper and pulley are initially balanced as an assembly.
Vibration Damper Balance Pins
If the crankshaft damper is being replaced, check if the original damper has balance pins installed. If so, new balance pins (EOSZ-6A328-A or equivalent) must be installed on the new damper in the same position as the original damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed.
8. Remove crankshaft pulley and vibration damper. Use Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B to remove vibration damper.
9. Remove hold-down clamp (12270) and camshaft position sensor (CMP)(6B288) and housing.
10. Remove valve covers (6582).
CAUTION: Do not damage machined sealing surfaces or leakage may occur.
NOTE: Before attempting to remove lower intake manifold, break seal between lower intake manifold and cylinder block (6010). Wedge a large prybar between lower intake manifold and cylinder block. Pry downward on prybar using lug on water pump as a leverage point.
11. Remove lower intake manifold and intake manifold gasket (9439). Discard intake intake manifold gasket and end seals.
12. Remove spark plugs.
NOTE: The location of each rocker arm, push rod and rocker arm seat (6A528) should be noted. When engine is assembled, each component should be installed in its original position.
13. Remove rocker arms (6564) and push rods (6565).
14. Remove cylinder heads (6049). Discard cylinder head retaining bolts. Remove and discard head gaskets (6051).
NOTE: The location of each valve tappet should be identified. When engine is assembled, each valve tappet should be installed in its original position. If valve tappets are stuck in bores due to excessive varnish or gum deposits, it may be necessary to use a magnet or a claw-type tool to aid removal. When using a remover tool, rotate valve tappet back and forth to loosen it from any gum or varnish that may have formed on valve tappet.
15. Remove tappet guide plates and retainers (6K564) and valve tappets (6500).
16. Remove oil bypass filter (6714).
17. Remove oil pan (6675).
18. Remove oil pump screen cover and tube (6622). Discard gasket (6626).
19. Remove water pump and engine front cover (6019) as an assembly. Discard engine front cover gasket.
20. Remove camshaft sprocket retaining bolt and washer from end of camshaft (6250). Remove distributor drive gear (6255).
CAUTION: Do not damage finished areas on crankshaft (6303) and crankshaft sprocket (6306).
NOTE: If crankshaft sprocket is difficult to remove, it can be loosened by prying using two large pry bars.
Distributor Gear:
21. Remove camshaft sprocket (6256), crankshaft sprocket and timing chain at the same time.
22. Pull back on ratcheting mechanism and install a pin through hole in bracket to relieve tension.
23. Remove timing chain vibration damper (6284) (three bolts) from front of cylinder block (6010).
24. Remove camshaft thrust plate (6269).
CAUTION: Do not damage camshaft bearing surfaces or engine damage may occur.
25. Remove camshaft.
26. If necessary, remove camshaft rear bearing cover (6266) from back of engine.
27. Inspect top of cylinder bores. Remove ridge and/or carbon deposits from each cylinder if necessary.
CAUTION: Never cut into ring travel area in excess of 0.794mm (0.0325 inch) or damage to the cylinder block may occur.
. Turn crankshaft until piston is at bottom of its stroke.
. Cover piston with a clean shop towel to collect cuttings.
. Remove ridge and/or carbon deposits from each cylinder using cylinder ridge reamer T64L-6011-EA or an equivalent.
. After cutting operation, turn crankshaft until piston is at top of its stroke and remove shop towel with cuttings.
CAUTION: Mark the location of each piston, connecting rod bearing (6211) and connecting rod cap. When engine is assembled each component should be installed in its original position.
28. Remove connecting rod caps and install connecting rod guide tool over connecting rod bolt holes and push piston out through the top of the cylinder bore
CAUTION: Mark the location of crankshaft main bearings (6333). When engine is assembled each crankshaft main bearing should be installed in its original position. Use care to prevent damage to crankshaft bearing surface(s).
29. Remove crankshaft main bearing caps and crankshaft.
NOTE: For cleaning purposes, oil gallery and cooling jacket plugs can be removed.
30. Clean and inspect pistons, connecting rods (6200), crankshaft and cylinder block.
31. Refinish or replace components as required.