Disassembly

Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.

1. Remove flywheel (6375) and engine rear plate (7007).
2. Remove intake manifolds (9424).
3. Remove LH and RH exhaust manifolds.

NOTE: When LH exhaust manifold (9430) is removed, note location of oil level indicator tube support bracket.

4. Disconnect front evaporative emission hose and remove the following positive crankcase ventilation system components:
- Front and rear crankcase ventilation tube (6758).
- Positive crankcase ventilation valve (PCV valve)(6A666).

5. Disconnect water bypass tube (85483 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).
6. Disconnect ignition wires from spark plugs.

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.

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 (9F593) and fuel injection supply manifold (9F792)

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.

NOTE:
- 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.
- If the crankshaft damper is being replaced, check if the original damper has balance pins installed. If so, new balance pins (E0SZ-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.

9. Remove hold-down clamp (12270) and camshaft position sensor (CMP sensor)(6B288) and housing.
10. Remove valve covers (6582).
11. Remove lower intake manifold and intake manifold gasket (9439). Discard intake intake manifold gasket and end seals.

CAUTION: Do not damage machined sealing surfaces or possible leakage may occur.

NOTE: Before attempting to remove lower intake manifold, break seal between lower intake manifold and cylinder blocks (6010). Wedge a large prybar between lower intake manifold and cylinder blocks. Pry downward on prybar using lug on water pump as a leverage point.

12. Remove spark plugs.
13. Remove rocker arms (6564) and push rods (6565). 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.
14. Remove cylinder heads (6049). Discard cylinder head retaining bolts. Remove and discard head gaskets (6051).
15. Remove tappet guide plates and retainers (6K564) and valve tappets (6500).

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.

16. Remove oil bypass filter (6714).
17. Remove oil pan (6675).
18. Remove oil pump screen cover and tube (6622). Discard oil pump inlet tube gasket (6626).
19. Remove water pump and engine front cover (6019) as an assembly. Remove and discard engine front cover gasket.

After removing engine front cover, remove camshaft sprocket retaining bolt and washer from end of camshaft (6250).

Distributor Gear:

20. Remove distributor drive gear (6255). Remove camshaft sprocket (6256), crankshaft sprocket and timing chain at the same time.

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 prybars.

21. Remove timing chain vibration damper (6284) from front of cylinder blocks. (This requires pulling back on ratcheting mechanism and then installing pin through hole in bracket to relieve tension.)





22. Remove camshaft thrust plate (6269).
23. Remove camshaft.

CAUTION: Do not damage camshaft bearing surfaces or engine damage may occur.

24. If necessary remove camshaft rear bearing cover (6266j from back of engine.





25. Remove connecting rod caps and pistons. The location of each piston, connecting rod bearings (6211) and connecting rod cap should be noted. When engine is assembled, each component should be installed in its original position.

CAUTION: Never cut into ring travel area in excess of 0.794 mm (0.0325 inch) or damage to piston rings or cylinder blocks may occur.

NOTE: Before removing pistons (6108), inspect top of cylinder bores. If necessary, remove ridge and/or carbon deposits from each cylinder using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent. Before ridge or deposits are removed, turn crankshaft until piston is at bottom of its stroke. Cover piston with a clean shop towel to collect cuttings. After cutting operation, turn crankshaft until piston is at top of its stroke and remove shop towel with cuttings.

26. Remove main bearing caps and crankshaft. The location of crankshaft main bearings (6333) should be identified. When engine is assembled, each crankshaft main bearing should be installed in its original position.
27. For cleaning purposes, oil gallery and cooling jacket plugs can be removed.