Disassembly
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Special Tool(s)
CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
1. Illustration 1 of 14. Remove the components in the order indicated.
2. Install the engine on a suitable engine stand and remove the engine lifting eyes.
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3. Illustration 2 of 14. Remove the components in the order indicated.
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4. Illustration 3 of 14. Remove the components in the order indicated.
5. Illustration 4 of 14. Remove the components in the order indicated.
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6. Illustration 5 of 14. Remove the components in the order indicated.
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7. Illustration 6 of 14. Remove the components in the order indicated.
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8. Illustration 7 of 14. Remove the components in the order indicated.
9. Illustration 8 of 14. Remove the components in the order indicated.
10. Illustration 9 of 14. Remove the components in the order indicated.
11. Illustration 10 of 14. Remove the components in the order indicated.
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12. Illustration 11 of 14. Remove the components in the order indicated.
13. Illustration 12 of 14. Remove the components in the order indicated.
14. Illustration 13 of 14. On 4x4 vehicles only, remove the components in the order indicated.
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15. Illustration 14 of 14. Remove the components in the order indicated.
Item 11: Crankshaft Pulley Disassembly Note
1. Using the special tool, remove the crankshaft dampener.
Item 13: Generator B+ Terminal Disassembly Note
1. Disconnect the oil pressure switch electrical connector and remove the battery cable and harness.
2 Remove the oil pressure switch.
Item 23: Electrical Connectors Disassembly Note
1. Disconnect the following:
^ Camshaft Position (CMP) sensor electrical connector.
^ Ignition coil electrical connector.
^ Pin-type retainer.
Item 24: Ignition Wires Disassembly Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
Remove the spark plug wires.
Item 44: RH Exhaust Manifold Disassembly Note
1. Remove the three bolts and the RH engine insulator bracket.
Item 70: LH Exhaust Manifold Disassembly Note
1. Remove the three bolts and the LH engine insulator bracket.
Item 75: Camshaft Roller Followers Disassembly Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Item 76: Hydraulic Lash Adjuster Disassembly Note
1. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Remove the hydraulic lash adjusters.
Item 79: Jackshaft Sprocket Bolt Disassembly Note
1. Using the special tool, hold the crankshaft.
2. Remove the rear jackshaft sprocket bolt.
3. Remove the rear bolt and spacer.
Item 81: Camshaft Sprocket Bolt Disassembly Note
1. Install the special tools on the RH cylinder head.
2. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.
Loosen the camshaft sprocket bolt.
3. Remove the camshaft sprocket bolt.
1 Remove the special tools.
2 Remove the camshaft sprocket bolt.
4. Separate the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
Item 85: Camshaft Sprocket Bolt Disassembly Note
1. Install the special tools on the LH cylinder head.
2. Loosen the camshaft sprocket bolt.
3. Remove the camshaft sprocket bolt.
1 Remove the special tools.
2 Remove the camshaft sprocket bolt.
4. Separate the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
Item 86: Jackshaft Sprocket Bolt Disassembly Note
1. Using the special tool, keep the crankshaft from turning while loosening the jackshaft sprocket bolt.
2. Remove the jackshaft thrust plate bolts and the jackshaft thrust plate.
Item 89: Primary Chain Guide Disassembly Note
1. Remove the primary chain guide bolts and the primary chain guide.
Items 96 and 99: LH and RH Cylinder Head Bolts Disassembly Note
1. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Remove the bolts in the sequence shown and remove the cylinder head.
Items 97 and 100: LH and RH Cylinder Head Disassembly Note
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean and inspect the sealing surfaces.
Item 114: Oil Pump Disassembly Note
1. Remove the oil pump pick-up tube, the oil pump, and the oil pump intermediate shaft.
2. Remove the bolt, the clamp, and the oil pump drive assembly.
Item 115: Balance Shaft Tensioner Bolts Disassembly Note
1. Install a pin in the balance shaft tensioner.
Item 117: Balance Shaft Drive Chain Disassembly Note
1. NOTE: DO NOT remove the balance shaft sprocket bolt.
Remove the balance shaft chain and crankshaft sprocket.
Item 126: Piston Connecting Rod Bearing Cap Nuts Disassembly Note
1. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder to allow removal of the piston(s).
Item 129: Piston Assembly Disassembly Note
1. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.