Disassembly

1. Remove the engine from the vehicle.
2. Remove the throttle body coolant line.
3. Remove the idle air control bypass air (IAC BRA) valve coolant line.
4. Remove the positive crankcase ventilation valve (PCV valve) from the valve cover.
5. Disconnect the EGR vacuum control connector from the intake manifold.
6. Remove the five intake manifold bolts and two nuts.
7. Remove the intake manifold and discard the intake manifold gasket.





8. Remove the oil pressure switch.
9. Remove the oil filter.
10. Disconnect the water bypass hose from the water hose connection.
11. Remove the engine lifting eyes.
12. Remove the water hose connection bolts and the water hose connection. Remove and discard the water hose connection gasket.
13. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold.
14. Disconnect the distributor to spark plug wires from the spark plugs.
15. Remove the spark plugs.
16. Remove the distributor and discard the distributor O-ring.
17. Disconnect the upstream heated oxygen sensor (H02S) electrical connector.





18. Remove the exhaust manifold shield.





19. Remove the eight exhaust manifold bolts and two nuts. Remove the exhaust manifold.
20. Discard the exhaust manifold nuts and exhaust manifold gasket.
21. Remove the water inlet connection along with the water bypass hose and the heater hot water tube. Discard the water inlet connection gasket.





22. Remove the valve cover bolts in two steps, in the sequence shown.
23. Remove the valve cover and discard the valve cover gasket.





24. Use Water Pump Pulley Tool T92C-6312-AH to remove the water pump pulley.
25. Remove the upper engine front cover.
26. Remove the lower engine front cover.
27. Loosen the timing belt tensioner and timing belt tensioner spring.

NOTE: If the timing belt is to be reused, mark the direction of rotation.

28. Remove the timing belt.
29. Remove the timing belt tensioner and timing belt tensioner spring.
30. Remove the RH engine support insulator mounting bracket.
31. Remove the oil level indicator tube.
32. Remove the crankshaft CKP sensor bolt and move the CKP sensor aside.
33. Remove the crankshaft sprocket and timing chain guide.
34. Rotate each camshaft until all lobes are in the neutral position (no pressure applied on the hydraulic lash adjusters (HLA)).





35. Remove the two camshaft sprockets.

NOTE: Hold the camshaft by using a wrench on the hexagon which is cast on the camshafts.





36. Remove the sixteen camshaft bearing cap bolts and four camshaft thrust plate bolts in two steps, in the sequence shown.

NOTE: The camshaft bearing caps and camshaft thrust plates are stamped with numbers to ensure correct placement during installation.





37. Remove the two camshaft thrust plates and the eight camshaft bearing caps.
38. Remove the two camshaft front seals from the front camshaft bearing caps.
39. Remove the camshafts.





40. Remove the ten cylinder head bolts in the sequence shown.
41. Remove the cylinder head and discard the head gasket.
42. Remove the oil pan bolts and the oil pan.

(Part 3 Of 3):

43. Remove the oil pump screen cover and tube and discard the oil pump inlet tube gasket.
44. Remove the stiffener bolts in two steps, in the sequence shown.
45. Remove the stiffener.
46. Remove the seven oil pump bolts and remove the oil pump.
47. Remove the timing belt idler.
48. Remove the five water pump bolts. Remove the water pump and discard the water pump housing gasket.
49. Use Cylinder Ridge Reamer T64L-6011-EA, if necessary. If a ridge has formed at the top of the cylinder it must be removed before the piston removal. Remove the ridge as follows:
a. Turn the crankshaft until the piston to be removed is at the bottom of the cylinder bore.
b. Place a clean shop cloth over the piston head to collect cuttings.
c. Remove the ridge using Cylinder Ridge Reamer T64L-6011-EA. Never cut into the ring travel area more than 0.8 mm (1/32 inch) when removing the ridge.

(Part 3 Of 3):

50. Remove the connecting rod bearing cap bolts and the connecting rod bearing caps.

NOTE: The connecting rod bearing caps and connecting rods are stamped with alignment marks. Ensure the connecting rod bearing caps are placed with matching connecting rods.

51. Remove the pistons.

NOTE: Place the pistons with their respective connecting rod bearing caps.

52. Use Seal Remover T92C-6700-CH to remove the crankshaft rear oil seal from the crankshaft rear oil seal retainer.
53. Remove the crankshaft rear oil seal retainer.





54. Remove the crankshaft main bearing cap bolts in two steps, in the sequence shown.
55. Remove the crankshaft main bearing caps.
56. Remove the lower crankshaft main bearings.
57. Remove the crankshaft.
58. Remove the upper crankshaft main bearings and the crankshaft thrust bearings.





59. Use Oil Jet Remover T92C-6327-CH and Cross Bar Oil Jet Remover/Replacer T92C-6327-AH to remove the four piston cooling oil jets.