Steps 56 - 106

56. Remove the bolts and the generator.





57. Remove the bolts, the oil pan and the oil pan gasket.
- Discard the gasket.





58. Remove the bolts, the engine front cover and the gasket.
- Discard the gasket.





59. Remove the ignition pulse ring.





60. CAUTION: Rotating the crankshaft in a counterclockwise direction can cause possible engine damage. Crankshaft journals are directionally machined. Rotating the crankshaft counterclockwise can raise burrs on bearing surfaces, reducing engine life.

CAUTION: If the RH timing chain tensioner arm and RH timing chain guide are to be reused, mark position of each to make sure of original position when reassembled.

Compress the timing chain tensioner.
1 Release the racketing pawl.
2 Compress the timing chain tensioner and install a stiff wire or paper clip





61. Remove the bolts, the timing chain tensioner and the tensioner arm.
62. Remove the RH timing chain





63. Remove the bolts and the RH timing chain guide





64. CAUTION: If the LH timing chain tensioner arm and the LH timing chain guide are to be reused, mark position of each to make sure of original position when reassembled.

Compress the timing chain tensioner.
1 Release the racketing pawl.
2 Compress the timing chain tensioner and install a stiff wire or paper clip.





65. Remove the bolts, the timing chain tensioner and the tensioner arm.





66. Remove the LH timing chain.
67. Remove the bolts and the LH chain guide.





68. Remove the crankshaft sprocket.

69. NOTE: LH side shown; RH side similar

CAUTION: Remove the camshaft journal thrust caps prior to loosening other camshaft journal cap bolts. Damage to the camshaft journal thrust cap can occur if not removed first.

CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to be sure they are assembled in their original position. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.

Remove the LH and RH camshaft thrust cap bolts

NOTE: LH side shown; RH side similar.

NOTE: The camshaft journal thrust caps have alignment dowels.





70. Using a soft-faced mallet, gently loosen and remove the LH and RH camshaft journal thrust caps.





71. NOTE: LH side shown; RH side similar.

Remove the remaining bolts.





72. NOTE: LH side shown; RH side similar.

Using a soft-faced mallet, gently loosen and remove the remaining camshaft journal caps.





73. CAUTION: If the bucket tappets are to be reused, mark the position of the bucket tappets to make sure they are assembled in their original positions.

NOTE: LH side shown; RH side similar.

Carefully lift out the LH and RH intake and exhaust camshafts.





74. Remove the stud bolt and the oil level indicator tube.





75. Remove the bolts and the coolant bypass tube.





76. Remove the PCV tube stud.





77. If equipped, remove the bolts and the LH heat shield.





78. If equipped, remove the bolts and the RH heat shield.





79. NOTE: RH side shown; LH side similar.

Remove the nuts and the RH and LH exhaust manifolds and gaskets.
- Discard the gaskets.





80. Remove the bolts and the RH and LH cylinder heads.
- Discard the gaskets.





81. Remove the one stud, two bolts and the RH engine mount bracket.





82. Remove the oil pressure switch.





83. Remove the bolts and the A/C compressor mounting bracket.





84. Remove the oil filter.





85. Remove the bolts and the oil filter adapter.





86. Remove the bolts and the inlet tube.





87. Remove the bolts and the oil separator.
- Discard the gasket.





88. Remove the bolt and the top-mounted KS.





89. Remove the bolts and the oil pick-up tube.
- Inspect the O-ring seal for damage.





90. Remove the nuts and the oil pan baffle.





91. Using the special tool, remove the cylinder ridge.

92. CAUTION: Pistons,connecting rods, connecting rod bearings and caps should be marked to be sure they are assembled in their original locations.

Turn crankshaft until the piston to be removed is at the low point of its travel near the oil pan mounting.





93. NOTE: Connecting rod bearing caps are cracked and split from the connecting rods during manufacture, thereby providing an exact fit to the connecting rod when assembled. Care should be taken to prevent dirt or grease from contaminating the cap and rod mating surfaces. Identification marks on the cap and rod must remain aligned as a matched set during assembly.

Remove the connecting rod cap retaining bolts, connecting rod cap and lower connecting rod bearing. Keep the cap and bearing together.





94. Using the special tool to protect the cylinder, push the piston, connecting rod and upper bearing assembly through the top of the cylinder bore.





95. CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage can occur.

CAUTION: New connecting rod bolts must be installed. They are torque-to-yield and cannot be reused.

Connecting rod bolts are retained in the connecting rod caps with a slight press fit. Using a hammer and punch, drive the bolts from the caps.





96. Using new connecting rod bolts, attach the connecting rod cap and lower bearing to the connecting rod and upper bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
97. If new piston rings must be installed, or piston and connecting rod disassembly is required.





98. Remove the bolts and the oil pump.





99. CAUTION: The bolts are torque-to-yield and cannot be reused. New bolts must be installed.

NOTE: Note the location of the stud bolts for assembly.

Remove the lower cylinder block.
1 Remove and discard the stud bolts.
2 Remove and discard the 17 bolts.
- Remove the lower cylinder block.





100. NOTE: If bearings are to be reused, mark the position of the upper and lower crankshaft main bearings and crankshaft thrust bearing.

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





101. Carefully remove the crankshaft from the upper cylinder block.
102. Remove and discard the crankshaft rear oil seal.





103. Remove the upper crankshaft bearings and thrust bearing from the upper cylinder block.





104. If necessary, remove the crankshaft key from the crankshaft keyway.
105. Remove the pipe plugs, engine block heater, and dowels from the cylinder block as necessary to clean foreign material from the oil and coolant passages.
106. Inspect the crankshaft, cylinder block and cylinder heads.