Part 3

Engine














NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

66. Slide the LH VCT (Variable Camshaft Timing) assemblies and secondary timing chain forward 2 mm (0.078 in).





67. Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.





68. Remove the LH VCT (Variable Camshaft Timing) assemblies and the LH secondary timing chain.





69. NOTICE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

Remove the 4 bolts and the LH front camshaft bearing mega cap.






70. Remove the 16 bolts and the 8 camshaft bearing caps.





71. NOTE: Intake camshaft shown, exhaust camshaft similar.
Remove the VCT (Variable Camshaft Timing) system oil filter from the intake and exhaust camshafts.






72. Remove the LH intake and exhaust camshafts.





73. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.





74. Remove the 2 bolts and the coolant outlet from the LH cylinder head.
- Remove and discard the gasket.






75. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the 10 bolts and the LH cylinder head.
- Discard the bolts and the cylinder head gasket.






76. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or notices and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.


77. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.





78. Remove the 2 bolts and the 2 KS (Knock Sensor).





79. Remove the bolt and the Crankshaft Position (CKP) sensor.





80. Remove and discard the oil filter.

Boss(R) 302 engines

81. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

Remove the threaded fitting and the oil cooler.
- Discard the oil cooler.






All engines

82. Remove the 3 bolts and the oil filter adapter.
- Discard the gasket.






83. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the bolts and the oil pan.
- Clean and inspect the sealing surface.






84. Remove the 3 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.






85. Remove the oil pump screen and pickup tube spacer.





86. Remove and discard the oil pan baffle and gasket.





87. Remove the 6 bolts and the crankshaft rear seal retainer plate.

- NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean and inspect the sealing surfaces.






88. Remove the 2 bolts, the 2 stud bolts and the oil pump.





89. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.

90. NOTICE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in engine damage.

Remove the bolts and the connecting rod cap. Discard the bolts.






91. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Use the Connecting Rod Installer to push the piston through the top of the cylinder block.






92. Repeat the previous 2 steps for each of the remaining pistons.

93. Disassemble the 8 pistons. For additional information, refer to Piston .

94. Remove the fasteners.
1. Remove and discard the cross-mounted main cap bolts.

2. Remove and discard the main bearing cap bolts and stud bolt.






95. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).





96. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.





All engines except Boss(R) 302

97. Remove the 4 bolts and 4 piston cooling jets from the cylinder block.





Boss(R) 302 engines

98. Remove the 4 bolts and 4 oil plugs from the cylinder block.