Cylinder Block - Removal

- Tools Required, or equivalent:
J 1859-03 Crankshaft Pulley Puller
J 24270 Ridge Reamer
Or Equivalents

1. Engine from vehicle.
2. Four bolts and power steering pump bracket (if equipped).





3. Loosen coolant pump pulley adjusting bolt, pivot bolt and lock bolt and Remove generator/coolant pump drive belt.
4. Air conditioning (A/C) compressor bracket from cylinder block (if equipped). See Heating and Cooling.





5. Two bolts and engine wiring harness cover.
6. Engine wiring harness from cylinder head cover.
7. Secondary (spark plug) wires.
8. Spark plugs from cylinder head.
9. Two hose clamps and Positive Crankcase Ventilation (PCV) hoses from cylinder head cover.
10. Four cap nuts, seal washers and cylinder head cover with gasket from cylinder head.
11. Four bolts and coolant pump pulley from coolant pump.
12. Crankshaft pulley using a crankshaft pulley puller.
13. Nine bolts and timing belt covers from engine.





NOTE: If timing belt is to be reused, mark timing belt with arrow showing direction of engine revolution. Put matchmarks where timing belt meets with crankshaft timing gear and camshaft timing gear to ensure installation in the same position.





14. Slide timing belt guide from crankshaft.





15. Idler pulley bolt, idler pulley and tension spring.

CAUTION: Do not bend, twist or turn the timing belt inside out. Do not allow the belt to come in contact with oil, coolant or steam. Do not use timing belt tension when removing or installing mounting bolts.

16. Timing belt from camshaft and crankshaft timing gears.

CAUTION: Take care not to damage the cylinder head when holding the camshaft in place.

17. Camshaft timing gear bolt while holding camshaft by the hexagonal wrench head section.
18. Crankshaft timing gear using two flat-bladed screwdrivers to pry off.
19. Camshafts.

CAUTION: Cylinder head warping or cracking could result from incorrect removal.





20. Cylinder head bolts in several passes using the sequence shown.

CAUTION: Do not damage cylinder head or cylinder block mating surfaces with pry bar when removing cylinder head.





21. Cylinder head from dowels on cylinder block with intake and exhaust manifolds placed on wooden blocks on workbench. If head is difficult to lift off, gently pry with a bar between the cylinder head and the cylinder lock projection.
22. Three bolts and generator bracket from cylinder block.
23. Three bolts and engine mount-to-cylinder block brace.
24. Three bolts, coolant pump and O-ring from cylinder block.
25. Oil filter.
26. Oil pressure switch from cylinder block.

CAUTION: When removing oil pan with a screwdriver, do not damage the oil pan flange.

27. Oil pan, baffle plate, oil pump screen and powertrain reinforcement brace.
28. Unclip crankshaft position sensor electrical connector from guide tube.
29. One bolt and guide tube with oil level indicator from oil pump.
30. Seven bolts and oil pump, with gasket, from cylinder block. If necessary, tap on back side of oil pump with a plastic or rubber-faced hammer to loosen it from the cylinder block.
31. Oil seal from oil pump.





32. Six bolts and rear main seal retainer.
33. Mark all piston heads with number of cylinder for installation in the same location.

CAUTION: Decarbon the top of the cylinder bores using a ridge reamer before attempting to Remove piston on the cylinder.

34. Mark connecting rods and connecting rod bearing caps with number of cylinder installation in the original location.
35. When removing pistons, keep all parts together in sets by cylinder and reinstall in the original location.
36. Eight nuts and four connecting rod bearing caps from connecting rods. Keep lower connecting rod bearings with connecting rod caps.

CAUTION: Install a piece of hose over threads of rod bolts. This is to prevent damage to threads, crankshaft and cylinder bore. Remove hose after removal of connecting rod.

37. Piston and connecting rod assembly through the top of the cylinder bore.
38. Upper connecting rod bearing from connecting rod.





NOTE: Loosen the main bearing cap bolts in several passes using the sequence shown.

39. When removing main bearings, keep all parts together in sets by cylinder and reinstall in the original location.
40. Ten main bearing cap bolts and five main bearing caps with lower main bearing halves and lower thrust washers from cylinder block.
41. Crankshaft from cylinder block.
42. Five upper main bearing halves from cylinder block.
43. Upper thrust washers from cylinder block (No. 3 main journal).