Disassembly

Special Tools:

Special Tools:

Disassembly
1. Remove the clutch and pressure plate.





2. Remove the flywheel.





3. Using the special tool, remove the rear oil slinger.





4. Using the special tool, remove the rear main seal.





5. Remove the rear seal retainer plate.





6. Mount the engine on a work stand.
7. Remove the special tools.





8. Disconnect the Positive Crankcase Ventilation (PCV) tube.





9. Remove the PCV valve tube.





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





11. Disconnect the EGR tube from the exhaust manifold.





12. Disconnect the fuel pressure damper.





13. Disconnect the EGR vacuum regulator.





14. Disconnect the four LH fuel injectors.





15. Remove the coil cover.





16. Disconnect the generator.





17. Disconnect the Idle Air Control (IAC) valve.





18. Disconnect the Throttle Position (TP) sensor.





19. Remove the upper intake manifold.





20. Remove the upper intake manifold gasket.
^ Clean and inspect the sealing surfaces.





21. Remove the RH coil cover.





22. Disconnect the LH ignition coils.





23. Disconnect the four RH fuel injectors.





24. Disconnect the Engine Coolant Temperature (ECT) sensor.





25. Disconnect the RH ignition coils.





26. Remove the eight ignition coils.





27. Disconnect the knock sensor jumper harness from the fuel charging harness.





28. Remove the upper generator support bracket.





29. Remove the nuts from the cylinder head coolant bypass tube.





30. Remove the bypass tube.





31. Remove the generator.





32. Remove the eight bolts and the two studs in the sequence shown. Remove the lower intake manifold.





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





34. Remove the water pump from the cylinder block.
^ Inspect and clean the sealing surfaces.





35. Remove the bolt.





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





37. Using the special tool, remove the crankshaft front seal.





38. Remove the belt idler pulley.





39. Remove the bolts and the LH valve cover.





40. Remove the bolts and the RH valve cover.





41. Remove the knock sensor harness.
1 LH knock sensor connector.
2 RH knock sensor connector.
3 Engine control sensor wiring connector.
4 Fuel injector connector.
5 A/C compressor connector.
6 Crankshaft position sensor connector.





42. Remove the knock sensors.





43. Remove the four bolts.











44. Remove the engine front cover.

45. Note: Be careful when removing the gasket. It is reusable if not damaged.





Remove the oil pan and the gasket.





46. Remove the crankshaft position sensor (cap) pulse wheel.





47. Using the special tool, remove the 32 roller followers.





48. Release the ratchet lock while the piston is being compressed.





49. Remove the RH and LH timing chain tensioner.
1 Compress the timing chain tensioner and install the retaining pins.
2 Remove the bolts and remove the timing chain tensioner.





50. Remove the RH and LH timing chain tensioner arms.





51. Remove the RH and the LH timing chains and crankshaft sprockets.





52. Remove the RH and LH timing chain guides.





53. Remove the RH and LH cylinder heads.





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





55. Remove the spacers and the windage tray.





56. Remove the bolts and remove the oil pump.

57. 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 in the following sequence.





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

58. 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 manufacturer's instructions.

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





Using the special tool, push pistons number 1 and 6 through the top of the cylinder block.
59. To remove pistons 3 and 5,4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat Steps 52, 53 and 54.





60. Remove the side bolts.





61. Remove and discard the bolts.





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





63. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.