Part 2

56. Detach the wiring harness retainers from the LH valve cover stud bolts.





57. Remove the 2 bolts and the LH coil-on-plug cover.





58. Disconnect the 4 LH coil-on-plug electrical connectors.
- Remove the 4 LH coil-on-plugs.





59. Remove the wiring harness assembly from the engine.
60. Disconnect the intake manifold-to-coolant tube assembly hose.





61. Remove the 14 bolts and the intake manifold assembly.
- Remove and discard the 2 intake manifold gaskets.





62. Remove the stud bolt, 3 bolts and the RH engine support insulator bracket.





63. Remove 8 nuts and the RH exhaust manifold.
- Discard the nuts and gaskets.
- Clean and inspect the RH exhaust manifold.





64. Remove the 4 bolts and the LH engine support insulator bracket.





65. Remove 8 nuts and the LH exhaust manifold.
- Discard the nuts and gaskets.
- Clean and inspect the LH exhaust manifold.





66. Remove the 3 coolant tube assembly bolts.





67. Remove the oil level indicator, the bolt and the oil level indicator tube.
- Remove and discard the oil level indicator tube O-ring seal.





68. Remove the coolant tube assembly-to-LH cylinder head bolt.





69. Remove the 3 bolts and the coolant tube assembly.





70. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

Remove the 6 bolts and the oil cooler.
- Discard the oil cooler and the gaskets.





71. Remove the 8 bolts and the oil filter adapter.
- Discard the oil filter adapter gasket.





72. NOTE: LH shown, RH similar.

Remove the LH and RH block drain plugs.





73. Remove the 14 bolts, 2 stud bolts and the oil pan.

- Remove and discard the oil pan gasket.

- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.





74. Remove the 3 bolts and the oil pump screen and pickup tube assembly.
- Discard the O-ring seal.





75. Remove the spacer, 7 nuts and the windage tray.





76. Remove the bolts, stud bolts and RH valve cover.
- Remove and discard the gaskets.

- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the mating surfaces.





77. Remove the bolts, stud bolts and LH valve cover.
- Remove and discard the gaskets.

- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.





78. Remove the bolt and the crankshaft position (CKP) sensor.





79. Remove the bolt and the CMP sensor.





80. Remove the 4 bolts and the coolant pump.





81. Using the special tool, remove the crankshaft pulley bolt and the washer.
- Discard the bolt.





82. Using the special tool, remove the crankshaft pulley.





83. Using the special tools, remove the crankshaft front seal.





84. Remove the 16 bolts and the engine front cover.
- Remove and discard the engine front cover gaskets.

- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.





85. NOTE: RH shown, LH similar.

Remove the 8 spark plugs.





86. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Using the special tool, compress the valve spring and remove the roller follower.





87. Repeat the previous step to remove each of the roller followers. Inspect roller followers.

88. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove the hydraulic lash adjusters.
- Inspect the hydraulic lash adjusters.





89. Remove the crankshaft sensor ring.





90. Remove the 2 bolts and the RH primary timing chain tensioner.





91. Remove the RH primary timing chain tensioner arm.





92. Remove the RH primary timing chain.





93. Remove the 2 bolts and the RH primary timing chain guide.





94. Remove the 2 bolts and the LH primary timing chain tensioner.





95. Remove the LH primary timing chain tensioner arm.





96. Remove the LH primary timing chain.





97. Remove the 2 bolts and the LH primary timing chain guide.





98. Remove the crankshaft sprocket.





99. Remove the 3 bolts and the oil pump.





100. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: LH shown, RH similar.

Remove the bolts, the RH cylinder head and the LH cylinder head.
- Discard the bolts.
- Remove and discard the cylinder head gaskets





101. 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 head 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.

102. 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 machine edge must be flat within 0.010 mm (0.0004 inch) from end to end.

NOTE: LH shown, RH similar.

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 head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).





103. 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 manufacturer's instructions.

104. NOTE: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation

Remove the bolts and the connecting rod caps for pistons No. 1 and No. 6.
- Carefully tap the connecting rod bolts out of the connecting rod caps. Avoid damaging the rod caps.





105. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Using the special tools, push the pistons 1 through 6 through the top of the cylinder block.





106. To remove pistons 2, 3, 4, 5, 7 and 8, turn the crankshaft 90 degrees and repeat the previous steps.

107. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

Remove the crankshaft main bearing cap fasteners.
1. Remove and discard the side bolts.
2. Remove and discard the main bearing cap bolts.
3. Remove the dowel pins.





108. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.





109. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.