Part 2
EngineDisassembly (Steps 42-82)
42. Remove the 6 bolts and the RH exhaust manifold.
^ Discard the gasket.
43. Remove the retainers and the RH valve cover.
44. Remove the retainers and the LH valve cover.
45. NOTE: Mark the location of the push rods and rocker arms before removing.
Remove the 12 rocker arms and 12 push rods.
46. Remove the 8 bolts and the lower intake manifold.
47. Remove and discard the lower intake manifold gaskets.
48. Remove the 4 bolts and the crankshaft pulley.
49. Remove the crankshaft damper bolt.
50. Remove the crankshaft position (CKP) sensor.
51. Using the special tool, remove the crankshaft damper.
52. Remove the oil filter.
53. Remove the 2 bolts and the valve tappet guide plate retainer.
54. Remove the 6 valve tappet guide plates.
55. NOTE: The valve tappets are positional. Identify each valve tappet for installation in the original position.
Remove the 12 valve tappets.
56. Remove the 2 screws and the CMP sensor.
57. Remove the camshaft synchronizer bolt.
58. NOTE: In some cases, the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
Remove the camshaft synchronizer.
59. Remove the 16 bolts and the oil pan.
60. Remove and discard the oil pan gasket.
61. Remove the 5 bolts and 5 stud bolts the engine front cover.
62. Remove the engine front cover gasket.
63. Remove the 8 bolts and the RH cylinder head.
64. Remove the 8 bolts and the LH cylinder head.
65. Remove and discard both cylinder head gaskets.
66. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
Remove the cylinder head bolts and the cylinder heads.
^ Remove and discard the head gaskets.
67. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
68. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61-cm (24-inch) long, the machined edge must be flat within 0.010 mm (0.0004 inch) from end to end.
Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1-mm (1.5-inch) square area, or scratches longer than 0.0254 mm (0.001 inch).
69. Remove the camshaft sprocket bolt.
70. Remove the timing sprockets and the timing chain as an assembly.
71. Remove the 2 bolts and the camshaft thrust plate.
72. Remove the camshaft.
73. If required, remove the camshaft bearings.
74. Remove the bolt and the oil pump.
75. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer instructions.
76. Remove the piston and connecting rod assemblies one at a time.
^ Remove the connecting rod nuts in pairs.
^ Remove the connecting rod cap.
^ Remove the piston and connecting rod assembly.
77. Remove the 8 main bearing cap bolts.
78. Remove the 4 main bearing caps.
79. Remove the lower crankshaft main bearings.
80. Remove the crankshaft rear seal.
81. Remove the crankshaft.
82. Remove the upper crankshaft main bearings.