Disassembly

Special Tool(s)

Disassembly

1. Remove the accessory drive belt.
2. Remove the bolt and the battery cables from the engine.





3. Disconnect the fuel charging wiring electrical connector from the crankshaft position (CKP) sensor.





4. Disconnect the fuel charging wiring electrical connector from the A/C compressor.





5. Remove the oil bypass filter.





6. Disconnect the electrical connection from the oil pressure sensor and the power steering pressure (PSP) switch, and detach the harness position retainer.





7. Disconnect the EGR tube from the exhaust manifold connector.





8. Disconnect the differential pressure feedback EGR sensor electrical connector.





9. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.





10. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.





11. Remove the bolts and the EGR tube heat shield.





12. Disconnect the vacuum lines for the evaporative emission (EVAP) canister purge valve, the main chassis line and the exhaust gas recirculation (EGR) valve.





13. Disconnect and remove the crankcase ventilation tube.





14. Disconnect the fuel charging wiring electrical connector from the EGR vacuum regulator solenoid.





15. Remove the generator mounting bracket.
^ Remove the bolts.
^ Remove the bracket.





16. Disconnect the electrical connector from the idle air control (IAC) and the throttle position (TP) sensor.





17. Disconnect the electrical connector from the generator.





18. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine assembly.





19. Disconnect the EGR tube nut from the EGR valve.





20. Remove the generator.
1. Remove the bolts.
2. Remove the generator.





21. Remove the bolt and nut; remove the wiring bracket.





22. Remove the four bolts and the throttle body.





23. Remove the bolt and the stud. Remove the crash bracket.





24. Remove the four studs and the fuel injection supply manifold and fuel injectors as an assembly.





25. Remove the eight bolts and the eight ignition coils.





26. Remove the bolts and the water outlet adapter.





27. Remove the water thermostat.





28. Remove the bolts and the intake manifold.





29. Remove the intake manifold gaskets.





30. Clean the sealing surfaces.





31. Remove the oil pan.
^ Remove the bolts.
^ Remove the oil pan.
^ Remove the oil pan gasket.





32. Remove the bolts and the oil pump screen cover and tube.





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





34. Remove the studs and bolts, and remove the valve cover.
^ Discard the valve cover gasket and clean the mating surface of the cylinder head.





35. Remove the studs and bolts and remove the right valve cover.
^ Discard the valve cover gasket and clean the mating surface of the cylinder head.





36. Remove the bolt and the studs and position the reservoir aside.





37. Remove the bolts and position the power steering pump aside.





38. Remove the bolt and the belt idler pulley.





39. Remove the water pump pulley.





40. Remove the bolts.





41. Remove the (A) water pump from the (B) cylinder block.





42. Remove the crankshaft pulley bolt.
Use the Crankshaft Damper Remover to remove the crankshaft pulley.





43. Remove the bolts and the A/C compressor.





44. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal.





45. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Remove the fasteners.





46. Remove the engine front cover from the cylinder block.





47. Remove the crankshaft sensor ring from the crankshaft.





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

Position the crankshaft with the Crankshaft Holding Tool as shown.





49. Remove the timing chain tensioning system from both timing chain.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.





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

Remove the LH and RH timing chains and the crankshaft sprocket.
^ Remove the Crankshaft Holding Tool.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Repeat for the LH timing chain and crankshaft sprocket.





51. Remove both timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.





52. Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket.





53. Remove the LH exhaust manifold.
1. Remove the nuts.
2. Remove the LH exhaust manifold.
3. Remove the LH exhaust manifold gaskets.





54. Remove the bolt and the oil level indicator tube.





55. CAUTION: Cylinder head bolts must be replaced with new bolts. They are tighten-to-yield designed and cannot be reused.

CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.

Remove the bolts and discard.
^ RH is shown. LH is similar.
^ Remove the cylinder head.
56. Discard the head gasket and clean the engine block surface.





57. Remove the bolts, and remove the LH engine mount.





58. Remove the bolts, and remove the RH engine mount.





59. Remove the bolts and the oil filter adapter and oil gasket.





60. Remove the oil pump.
1. Remove the bolts.
2. Remove the oil pump.





61. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for proper orientation.

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





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

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





63. Remove the crankshaft bearing cap fasteners.
1. Remove and discard the cross-mounted main cap bolts.
2. Loosen the jack screws.
3. Remove and discard the main cap bolts.





64. Remove the five main bearing caps and the lower crankshaft main bearings.





65. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.