Disassembly

1. Remove engine and install engine on engine stand, following manufacturer's instructions using Rotunda Powertrain Lift 014-00765 or equivalent.
2. Loosen four bolts retaining power steering pump pulley hub (3D674) to power steering pump (3A674) (DO NOT remove bolts).
3. Release front end accessory drive belt tension by rotating drive belt tensioner (6B209) clockwise.
4. Remove drive belt (8620).
5. Disconnect ignition wires from ignition coil (12029) and spark plugs (12405).
6. Release ignition wire separators from upper intake manifold (9424) and remove ignition wires as an assembly.
7. Remove A/C compressor mounting bolts from cylinder block (6010). Remove A/C compressor (19703).
8. Remove generator brace (10B315) from generator (GEN) (10300) and generator mounting bracket.
9. Remove generator from generator mounting bracket.





10. Remove generator mounting bracket retainers and bracket from cylinder block.
11. Remove engine lifting eye (17A084) from RH and LH cylinder heads (6049).
12. Rotate water pump drive belt tensioner clockwise to release water pump drive belt tension and remove water pump drive belt. Carefully release drive belt tensioner.





13. Using Crankshaft Damper Replacer T74P-6316-B and Water Pump Pulley Remover/Replacer T94P-6312-AH screws, remove water pump drive pulley from LH intake camshaft (6250).
14. Disconnect heated oxygen sensor (H02S)(9F472) from fuel charging wiring (9D930) and remove LH exhaust manifold retaining bolts and LH exhaust manifold gasket (9448) from LH cylinder head.





15. Remove oil level dipstick (6750), oil level indicator tube (6754) and O-ring from LH cylinder head and cylinder block.





16. Depress black collet with a small screwdriver on upper intake manifold and disconnect emission vacuum control connector assembly from upper intake manifold. Disconnect EGR vacuum regulator solenoid (9J459) from EGR vacuum regulator solenoid, EGR Valve (EGR valve)(9D475), and fuel pressure regulator vacuum connector. Remove emission vacuum control connector assembly from engine.
17. Disconnect EGR backpressure transducer hoses from EGR valve to exhaust manifold tube (9D477).
18. Remove retaining nut and ignition coil ground cable from EGR backpressure transducer mounting bracket retaining stud. Disconnect fuel charging wiring from EGR backpressure transducer and control solenoid vacuum valve.





19. Remove EGR backpressure transducer mounting bracket retainers and EGR backpressure transducer and mounting bracket as an assembly from the RH cylinder head.
20. Remove EGR valve to exhaust manifold tube EGR valve and RH exhaust manifold (9430).





21. Remove RH exhaust manifold retainers, RH exhaust manifold and exhaust manifold gasket from RH cylinder head.
22. Remove crankcase ventilation tube (6758) from intake manifold vacuum port connector.
23. Remove positive crankcase ventilation valve (PCV valve) (6A666) from oil separator crankcase ventilation tube.
24. If necessary, remove retainer bolts, EGR valve and EGR valve gasket (9D476).
25. Disconnect fuel charging wiring from throttle position sensor (TP) (9B989).
26. If necessary, remove throttle body retaining bolts and stud bolt, throttle body (9E926) and gasket from upper intake manifold.
27. If necessary, remove retaining bolts and EGR vacuum regulator solenoid from upper intake manifold.
28. Disconnect fuel charging wiring from idle air control valve (IAC valve) (9F715).
29. If necessary, remove idle air control valve retainer bolts, idle air control valve and gasket from upper intake manifold.





30. Remove upper intake manifold retaining bolts in sequence as shown. Remove upper intake manifolds and intake manifold upper gaskets (9H486) from lower intake manifold.
31. Disconnect fuel charging wiring from the following components:
- Engine coolant temperature sensor (ECT) (12A648).
- Ignition coil.
- Radio ignition interference capacitor (18801).
- Fuel injectors (9F593).
- Camshaft position sensor (CMP) (6B288).
- Oil pressure sensor (9278).
- Crankshaft position sensor (CKP) (6C315).





32. Remove fuel charging wiring and in-line connector bracket from RH valve cover retaining studs and engine assembly.
33. Disconnect emission vacuum control connector from fuel pressure regulator (9C968).
34. Disconnect IMRC actuator cable from runner control lever, cable bracket, water bypass stud and cable bridge.





35. Remove lower intake manifold (IMRC) retainer bolts in sequence shown from cylinder heads.
36. Remove lower intake manifold, fuel injectors and fuel injection supply manifold (9F792) as an assembly from cylinder heads.





37. Remove intake manifold gaskets (9439) from cylinder heads and discard.





38. Remove crankcase ventilation tube retaining nut and crankcase ventilation tube from oil separator (6B673) and water bypass tube stud bolt.
39. Loosen upper radiator hose spring clamp. Remove upper radiator hose from water bypass tube.





40. Remove water bypass tube to cylinder head retaining bolts and remove water crossover from cylinder head.
41. Loosen water pump outlet hose spring clamp. Remove water pump outlet hose from cylinder block inlet tube.

Part 1 Of 2:

Part 2 Of 2:

42. Remove water pump to LH cylinder head retaining bolts and remove water pump (8501).
43. Remove Ignition cold to RH valve cover retainer bolts. Remove radio ignition interference capacitor, ignition coil ground strap and ignition coil from RH valve cover (6582).
44. Remove bolts attaching IMRC electric actuator and cable assembly to LH valve cover.

Fig. 13 Valve cover bolt removal sequence:

45. Loosen RH and LH valve cover retainer bolts and studs in sequence as shown in the illustration. Remove RH and LH valve covers from cylinder head.





46. Remove camshaft rear oil seal retainer bolts and camshaft rear oil seal retainer and gasket from LH cylinder head.

NOTE: Replacement spark plugs are identical and can be installed in either cylinder head. See Powertrain Management.

47. Remove spark plugs from cylinder heads.
48. Remove power steering pump pulley retaining bolts and power steering pump pulley.
49. Remove four bolts and six nuts retaining power steering pump and brace to power steering pump bracket and engine front cover studs.





50. Remove power steering pump and brace from engine.
51. Remove crankshaft pulley retainer bolt and washer from crankshaft (6303).
52. Remove crankshaft pulley (6312) from crankshaft using Crankshaft Damper Remover T58P-6316-D.
53. If necessary, remove camshaft position sensor and crankshaft position sensor retaining bolts, camshaft position sensor and crankshaft position sensor from engine front cover (6019).
54. Remove oil bypass filter (6714).
55. Remove oil pressure sensor from cylinder block.
56. Remove oil pan drain plug and drain engine oil. Reinstall oil pan drain plug with new gasket. Tighten to 22-30 Nm (16-22 ft. lbs.).

CAUTION: To prevent residue in bottom of oil pan (6675) from entering engine, remove oil pan prior to turning engine upside down on engine stand.





57. Remove oil pan retaining bolts and stud bolts as shown in the illustration.
58. Remove oil pan and oil pan gasket (6710) from lower cylinder block.
59. If required, using Seal Remover T92C-6700-CH remove crankshaft front seal (6700) from engine front cover.
60. Remove drive belt idler pulley from RH side of engine front cover, if required.
61. Remove fuel charging wiring retainers from engine front cover retaining studs.





62. Remove engine front cover retaining bolts and studs in sequence as shown.
63. Remove engine front cover.
64. Remove crankshaft position sensor pulse ring from crankshaft.
65. Rotate the crankshaft to position the crankshaft keyway to the 11 o'clock location.
66. Verify the alignment arrows on the camshafts are aligned. If the arrows on the camshafts are not aligned, rotate the crankshaft one complete revolution.
67. Rotate crankshaft to position crankshaft keyway to the 3 o'clock location. This will position the RH cylinder head camshafts to the neutral position (base circle).
68. Remove LH and RH timing chain tensioner retaining bolts; then remove LH and RH timing chain tensioner (6L266).





69. Using a small screwdriver, release the timing chain tensioner ratchet/paw mechanism through the access hole in the timing chain tensioners.

NOTE: Timing chain tensioners must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioners prior to installation may cause damage to engine.

70. Compress plunger into tensioner housing until tip is below plate on end of ratchet mechanism. While holding plunger in compressed position, rotate plate and ratchet 180° so plunger can be released from tensioner housing. Slowly release plunger and remove it and plunger spring from housing.
71. Drain oil from tensioner housing and plunger cavity. Reassemble spring and plunger into housing. Compress tensioner into housing to bottom of bore. With plunger held at bottom of bore, rotate ratchet 180°, push back pawl with screwdriver and push ratchet down to contact plunger. Insert lock pin into hole in tensioner housing.

CAUTION:
^ Cylinder head camshaft journal caps and cylinder heads are numbered to make sure that they are assembled in their original positions. If removed, keep camshaft journal caps from each cylinder head together. Do not mix with camshaft journal caps from another cylinder head.
^ Remove the cylinder head camshaft journal thrust caps first to make sure damage to the cylinder head camshaft journal thrust caps does not occur.

72. Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from RH cylinder head.

Camshaft journal cap bolt removal sequence:

73. Loosen remaining RH cylinder head camshaft journal cap bolts, in sequence shown, seven to eight revolutions in several passes to allow camshafts to be raised from RH cylinder head. Do not remove retaining bolts completely.

CAUTION: If RH timing chain tensioner arm (6L253) and RH timing chain guide (6K297) are to be reused, mark position of timing chain tensioner arm and timing chain guide to make sure that they are assembled in their original positions.

Part 1 Of 2:

Part 2 Of 2:

74. Remove RH timing chain tensioner arm and RH timing chain.
75. Remove RH timing chain guide retaining bolts and RH timing chain guide.
76. Remove RH timing chain crankshaft sprocket (6306).

CAUTION: If valve tappets (6500) and roller rocker arms (6564) are to be reused, mark position of rocker arms and valve tappets to make sure that they are assembled in their original positions.

77. Remove RH cylinder head camshaft journal caps bolts and camshafts from RH cylinder head and remove rocker arms.
78. Remove valve tappets from RH cylinder head.
79. Remove RH timing chain tensioner arm and RH timing chain.
80. Rotate crankshaft two revolutions and position crankshaft keyway to the 11 o'clock location. This will position the LH cylinder head camshafts to the neutral position (base circle).
81. Verify the alignment arrows on the camshafts are aligned.

CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to make sure that they are assembled in their original positions. Keep camshaft journal caps from each cylinder head together. Do not mix with camshaft journal caps from another cylinder head.

CAUTION: Remove cylinder head camshaft journal thrust caps first to make sure that damage to the cylinder head camshaft journal thrust caps does not occur.

82. Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from LH cylinder head.
83. Loosen remaining LH cylinder head camshaft journal cap bolts in sequence shown in the illustration seven to eight revolutions to allow camshafts to be raised from LH cylinder head. Do not remove retaining bolts completely.

CAUTION: If LH timing chain tensioner arm and LH timing chain guide are to be reused, mark position of timing chain tensioner arm and timing chain guide to make sure that they are assembled in their original positions.

84. Remove LH timing chain tensioner arm and LH timing chain.
85. Remove LH timing chain guide retaining bolts and LH timing chain guide.
86. Remove LH timing chain crankshaft sprocket.

CAUTION: If valve tappets and roller rocker arms are to be reused, mark position of rocker arms and valve tappets to make sure that they are assembled in their original positions.





87. Remove LH cylinder head camshaft journal caps bolts and camshafts from LH cylinder head and remove rocker arms.
88. Remove valve tappets from LH cylinder head.





89. Remove cylinder head retaining bolts and washers in sequence shown.

NOTE: Cylinder heads should not be set on cylinder head face. Protect cylinder head face surface to avoid scratches and dents on cylinder head face sealing surfaces.





90. Remove cylinder heads from cylinder block.
91. Remove cylinder head gasket (6051) from cylinder block.
92. If required, disassemble cylinder heads.





93. Remove oil separator retaining bolts, oil separator and oil separator to cylinder block gasket (6B752) from cylinder block. Discard oil separator to cylinder block gasket.
94. Remove power steering pump bracket retaining bolts and power steering pump bracket from cylinder block.
95. If necessary, remove engine coolant inlet tube from cylinder block.
96. Turn engine over on engine stand.
97. Remove oil pump screen cover and tube support self-locking retaining nut and discard nut.





98. Remove oil pump screen cover and tube retaining bolts, oil pump screen cover and tube (6622) and O-ring from oil pump (6600).





99. Remove oil pan baffle retaining nuts and oil pan baffle (6687) from lower cylinder block retaining studs.

Fig. 34 Oil pump bolt removal sequence:

100. Remove oil pump retaining bolts in sequence shown. Remove oil pump from cylinder block. Inspect oil pump.

CAUTION: Pistons (6108), connecting rods (6200) and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.

NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA.

101. Turn crankshaft until piston to be removed is at the high point of its travel.

NOTE: Mark position of connecting rod cap to connecting rod for aid in reassembly.

102. If more than one piston is being removed identify the pistons, connecting rods and connecting rod caps for cylinder position.
103. Remove the connecting rod cap retaining bolts, connecting rod cap and lower connecting rod bearing. Keep connecting rod cap and lower connecting rod bearing together. Using Connecting Rod Guide Tool T94P-6136-AH installed into the connecting rod bolt holes, push the piston connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.

CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage may occur. Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.





104. Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at least twice and must be discarded. Using a hammer and punch, drive bolts from bolt holes.
105. Using a new connecting rod bolt, attach connecting rod cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
106. If piston ring replacement is required, replace piston rings.
107. If required, remove pistons from connecting rods.





108. Using Seal Remover T92C-6700-CH and a piece of thin copper shim stock 0.25 mm (0.010 inch) thick between the crankshaft and Seal Remover T92C-6700-CH, remove crankshaft rear oil seal (6701) from cylinder block.

CAUTION: Number 7 through number 18 are torque-to-yield bolts and should not be reused. Discard these bolts.





109. Using removal sequence, remove lower cylinder block retaining bolts.





110. Remove lower cylinder block from upper cylinder block.

NOTE: If bearings are to be reused, mark position of upper and lower crankshaft main bearings (6333) and crankshaft thrust main bearing (6337).

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

CAUTION: When removing crankshaft, use care not to damage any crankshaft journal bearing surfaces.

112. Remove crankshaft.
113. Remove upper crankshaft main bearings and crankshaft thrust washer (6334) from cylinder block.
114. If necessary, remove crankshaft key from crankshaft keyway.
115. If required, remove oil filter mounting insert (6890) from cylinder block.
116. Remove pipe plugs and alignment dowels from cylinder block as necessary to clean cylinder block and debris from oil passages.
117. Inspect crankshaft and cylinder block. Replace crankshaft and cylinder block as required.