Steps 46 - 95

46. Disconnect the vacuum lines from the EGR vacuum regulator solenoid.





47. Disconnect the EGR tube from the EGR valve.





48. Remove the bolts from the isolation valve.





49. Remove the four bolts.





50. Remove the fuel injection supply manifold and the fuel injectors as an assembly.





51. Disconnect the heater water hose from the intake manifold.





52. Disconnect the upper radiator hose from the water outlet adapter.





53. Remove the bolts and the eight ignition coils.





54. Remove the bolts and the upper generator support bracket.





55. Remove the bolts and the water outlet adapter.





56. Remove the water thermostat and the O-ring.





57. Remove the bolts.





58. Remove the intake manifold.





All engines

59. Remove the intake manifold gaskets





60. Clean the sealing surfaces.





61. Remove the oil pan.
^ Remove the bolts.
^ Remove the oil pan.
^ Remove the oil pan gasket.





62. Remove the bolts and the oil pump screen cover and tube.





63. Remove the oil pump screen cover and tube spacer.





64. Remove the studs and bolts, and remove the valve cover.
^ Discard the valve cover gasket and clean the mating surface of the cylinder head.





65. Remove the studs and bolts and remove the right valve cover.
^ Discard the valve cover gasket and clean the mating surface of the cylinder head.





66. Remove the bolt and the studs and position the reservoir aside.





67. Remove the bolts and set aside the power steering pump.





68. Remove the bolt and the belt idler pulley.





69. Remove the water pump pulley.





70. Remove the bolts.





71. Remove the (A) water pump from the (B) cylinder block.





72. Remove the bolts and the A/C compressor.





73. Remove the crankshaft pulley bolt.
^ Use the Crankshaft Damper Remover to remove the crankshaft pulley.





74. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal.





75. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Remove the fasteners.





76. Remove the engine front cover from the cylinder block.





77. Remove the crankshaft sensor ring from the crankshaft.





78. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Position the crankshaft with the Crankshaft Holding Tool as shown.





79. Remove the timing chain tensioning system from both timing chain.
1 Remove the bolts.
2 Remove the timing chain tensioners.
3 Remove the timing chain tensioner arms.





80. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Remove the LH and RH timing chains and the crankshaft sprockets.
^ Remove the Crankshaft Holding Tool.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain and outer crankshaft sprocket from the crankshaft.
^ Repeat for the LH timing chain and crankshaft sprocket.





81. Remove both timing chain guides.
^ Remove the bolts.
^ Remove both timing chain guides.





82. Remove the RH exhaust manifold.
1 Remove the nuts.
2 Remove the RH exhaust manifold.
3 Remove the RH exhaust manifold gasket.





83. Remove the LH exhaust manifold.
1 Remove the nuts.
2 Remove the LH exhaust manifold.
3 Remove the LH exhaust manifold gaskets.





84. Remove the bolt and the oil level indicator tube.





85. CAUTION: Install new cylinder head bolts. They are tighten-to-yield designed and cannot be reused.

CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.

NOTE: RH shown; LH similar.

Remove the bolts and discard.
^ Remove the cylinder head.
86. Discard the head gasket and clean the engine block surface.





87. Remove the bolts, and remove the LH engine mount.





88. Remove the bolts, and remove the engine mount.





89. Remove the bolts retaining the oil filter adapter and oil filter adapter gasket to the cylinder block.





90. Remove the oil pump.
1 Remove the bolts.
2 Remove the oil pump.





91. CAUTION: 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. Discard the bolts.





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

Use the Connecting Rod Guide Tool to push piston through the top of the cylinder block.





93. Remove the crankshaft bearing cap fasteners.
1 Remove and discard the cross-mounted main cap bolts.
2 Loosen the jack screws.
3 Remove and discard the main cap bolts.





94. Remove the five main bearing caps and the lower crankshaft main bearings.





95. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.