Part 3

Engine (continued)

107. Remove the left-hand camshaft position (CMP) sensor.
^ Remove and discard the O-ring seal.





108. CAUTION: Under no circumstances should the crankshaft setting peg 303-645 be used in the following operations to lock the crankshaft.

NOTE: The crankshaft retaining bolt will be very tight.

Using special tools, retain the crankshaft pulley.

^ Remove and discard the crankshaft pulley bolt.





109. Remove the special tools.

110. NOTE: The crankshaft pulley will be very tight.

Using special tools, remove the crankshaft pulley.

^ Collect the locking ring.
^ Remove and discard the O-ring seal.





111. Remove the crankshaft position (CKP) sensor.





112. CAUTION: Make sure the spark plugs are removed to enable the engine to rotate freely.

CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

CAUTION: Rotate the crankshaft clockwise to position the engine to top dead center (TDC) No. 1 cylinder.

Install the special tool 303-645.





113. Remove the right-hand valve cover.
^ Discard the valve cover gaskets.





114. Remove the left-hand valve cover.
^ Discard the valve cover gaskets.





115. Remove the engine front cover.





116. Remove the right-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.





117. Remove the left-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.





118. Install the special tool to the left-hand cylinder head.





119. Install the special tool to the right-hand cylinder head.





120. Remove the primary timing chain tensioner assembly.





121. Remove the primary timing chain tensioner guide.





122. Remove the primary timing chain.





123. Remove the primary timing chain guide.





124. Remove the secondary timing chain tensioner retaining bolts.





125. Remove the camshaft sprockets.
^ Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.





126. Remove the primary timing chain tensioner assembly.





127. Remove the primary timing chain tensioner guide.





128. Remove the primary timing chain.





129. Remove the crankshaft sprocket.





130. Remove the primary timing chain tensioner guide.





131. Remove the secondary timing chain tensioner retaining bolts.





132. Remove the camshaft sprockets.
^ Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.





133. Remove the camshaft setting tool.





134. Remove the camshaft setting tool.





135. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





136. Remove the right-hand exhaust camshaft.





137. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





138. Remove the right-hand intake camshaft.





139. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





140. Remove the left-hand exhaust camshaft.





141. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





142. Remove the left-hand inlet camshaft.





143. Remove the right-hand cylinder head.
^ Remove the bolts in the indicated sequence.
^ Remove and discard the gasket.





144. Remove the left-hand cylinder head.
^ Remove the bolts in the indicated sequence.
^ Remove and discard the gasket.





145. Remove the crankshaft setting peg 303-645 from the crankshaft position sensor location.





146. Remove the flexplate.
6. Remove the flexplate retaining bolts.
7. Remove the flexplate.





147. Remove the lower oil pan.
^ Remove and discard the gasket.





148. Remove the oil strainer.
^ Remove and discard the O-ring seal.





149. Remove the upper oil pan.
^ Remove and discard the gasket.





150. Remove the oil pump.
^ Remove and discard the gasket.





151. Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from each cylinder.
152. Remove the piston cooling jets.

153. CAUTION: Pistons, connecting rods and connecting rod bearings should be numbered to make sure they are reassembled in the same position.

NOTE: Mark the position of the connecting rod caps to the connecting rods to make sure of correct installation.

NOTE: Discard the connecting rod bolts after removal.

Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod bearings.





154. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surfaces.

Install special tools to the connecting rods.





155. CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage may occur. Avoid contaminating the fractured joint surfaces with dirt or grease.

NOTE: Attach the connecting rods and caps after removal to avoid mismatch.

Remove the pistons.

^ Rotate the crankshaft to locate pistons at the bottom of travel.
^ Push the piston, connecting rod and upper bearing through the top of the cylinder.





156. NOTE: Remove the lower cylinder block bolts in the indicated sequence.

NOTE: Mark the position of the upper and lower crankshaft main bearings for reassembly.

Remove the lower cylinder block.

^ Remove the lower cylinder block retaining bolts in the indicated sequence.





157. Discard the crankshaft rear main oil seal.





158. CAUTION: Avoid damage to any crankshaft bearing surfaces.

NOTE: Never remove any pipe, plugs or dowels unless they are to be newly installed or the cylinder block is to be washed.

Remove the crankshaft.





159. Remove the upper crankshaft main bearings.
8. Remove the upper crankshaft thrust washers.
9. Remove the upper crankshaft main bearings.





160. Clean the cylinder block with a soap and water solution. Dry the cylinder block completely with compressed air.