Disassembly

Special Tools:

1. Remove the breather tube.





2. Remove the EGR vacuum regulator solenoid.
1 Remove the vacuum lines.
2 Remove the electrical connector.
3 Remove the bolts.





3. Disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.





4. Disconnect the Positive Crankcase Ventilation (PCV) hose from the base of the throttle body.





5. Remove the PCV valve and hose as an assembly.

Part 1 Of 2:

Part 2 Of 2:

6. Remove the engine wiring harness.





7. Remove the throttle body bolts.





8. NOTE: The gasket is reusable if not damaged. Remove the throttle body and adapter as an assembly.

Inspect and clean the sealing surfaces.





9. Remove the four intake manifold studs.





10. Remove the injectors and fuel injection supply manifold as an assembly.





11. Remove the ignition coils.
12. Remove the accessory drive belt.





13. Remove the upper generator support bracket.





14. Loosen the bolts and remove the generator.





15. Disconnect the heater hose.





16. Remove the water outlet adapter.





17. Remove the water thermostat and O-ring.





18. Remove the bolts in the sequence shown, and remove the intake manifold.
- Clean and inspect the sealing surfaces.





19. Remove the oil cooler.
1 Remove the oil bypass filter.
2 Remove the bolts.
3 Remove the oil filter adapter.
4 Clean and inspect the sealing surfaces.





20. Remove the RH exhaust manifold.
1 Remove the exhaust manifold nuts.
2 Remove the exhaust manifold.
3 Remove the exhaust manifold gasket and discard.





21. Disconnect the Exhaust Gas Recirculation (EGR) tube at the exhaust manifold.





22. Remove the LH exhaust manifold.
1 Remove the exhaust manifold nuts.
2 Remove the exhaust manifold.
3 Remove the exhaust manifold gasket and discard.





23. Remove the oil level indicator tube bolt.





24. Remove the oil level indicator tube.





25. Remove valve cover.
- Remove the bolts.
- Remove the valve cover.





26. Remove valve cover.
- Remove the bolts.
- Remove the valve cover.





27. Remove the crankshaft pulley bolt.





28. Using the special tool, remove the crankshaft pulley.





29. Remove the water pump pulley.
1 Remove the water pump pulley bolts.
2 Remove the water pump pulley.





30. NOTE: The gasket can be reused if not damaged.

Remove the oil pan.
- Remove the bolts.
- Remove the oil pan.





31. Using the special tool, remove the front cover seal.





32. Remove the radio ignition interference capacitors.





33. Remove the bolts, the studs, and the engine front cover. Discard the gaskets, clean and inspect the sealing surfaces.

CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized.





34. Remove the crankshaft sensor ring from the crankshaft.





35. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.

Using the special tool, position the crankshaft as shown.





36. Install the special tool.





37. Remove the RH and LH timing chain tensioner (RH shown, LH similar)
1 Remove the bolts.
2 Remove the timing chain tensioners.
3 Remove the timing chain tensioner arms.





38. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Do not remove the special tool from the camshafts.

Remove the LH and RH timing chains and the crankshaft sprockets.
- Remove the special tool from the crankshaft.
- Remove the RH timing chain from camshaft sprocket.
- Remove the RH timing chain and the outer crankshaft sprocket from the crankshaft.
- Repeat for the LH timing chain and crankshaft sprocket.





39. NOTE: The LH is shown and the RH is similar.

Remove the bolts and the timing chain guides.





40. Remove the RH and LH cylinder heads.
- Remove the bolts.
- Remove the cylinder heads.





41. Remove the oil pump screen cover and tube and the spacer.





42. Remove the oil pump.





43. CAUTION: Do not stamp the top of pistons, as ring land damage may occur.

NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation.

Remove the connecting rod caps for piston number 1 and 6. Discard the bolts.





44. NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer following the tool manufacturer's instructions.

CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

Remove the piston pushing pistons number 1 and 6 through the top of the cylinder block.
45. Repeat steps 43 and 44 to remove the remaining pistons, rotating the crankshaft 90° between piston pairs 3 and 5, 4 and 7, 2 and 8.





46. Remove the fasteners.
1 Remove the side bolts.
2 Remove the main cap bolts.





47. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.





48. Remove the crankshaft main bearing.
1 Remove the crankshaft.
2 Remove the crankshaft thrust washer.
3 Remove the crankshaft main bearings.