Disassembly
EnginePart 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
Special Tool(s)
Disassembly
1. Remove the flexplate.
2. Using the special tool, remove the rear oil slinger.
3. Using the special tool, remove the rear cam seal.
4. Remove the rear seal retainer plate.
5. Mount the engine on an engine stand.
6. Remove the special tools.
7. Disconnect the Positive Crankcase Ventilation (PVC) tube.
8. Disconnect the EGR system module electrical connector.
9. Disconnect the vacuum hoses and the Positive Crankcase Ventilation (PCV) valve coolant hoses.
10. Remove the bolt and the bracket.
11. Disconnect the Exhaust Gas Recirculation (EGR) system module tube from the EGR system module.
12. Disconnect the EGR system module tube from the exhaust manifold.
13. Disconnect the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor electrical connectors.
14. Remove the upper intake manifold assembly bolts in the sequence shown and remove the intake manifold assembly.
15. Disconnect the coolant hoses, electrical connectors, and the wiring harness retainer.
16. Remove the accessory drive belt.
17. Remove the bolts and the generator support bracket.
18. Remove the crossover tube.
19. Remove the bolts and the generator.
20. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connectors.
21. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.
22. Separate the fuel charging wiring from the fuel injection supply manifold studs in three places.
23. Disconnect the eight fuel injector electrical connectors.
24. Remove the eight bolts and two studs in the sequence shown, and raise the lower intake manifold slightly.
25. Disconnect the fuel charging wiring harness from the rear of the lower intake manifold and remove the manifold.
26. Remove the LH coil cover.
27. Remove the RH coil cover.
28. Disconnect the LH ignition coils.
29. Disconnect the RH ignition coils.
30. Remove the eight ignition coils.
31. Disconnect the knock sensor from the fuel charging harness.
32. Remove the water pump pulley.
1 Remove the bolts.
2 Remove the water pump pulley.
33. Remove the water pump from the cylinder block.
^ Inspect and clean the sealing surfaces.
34. Remove the bolt.
35. Using the special tool, remove the crankshaft pulley.
36. Using the special tool, remove the crankshaft front seal.
37. Remove the belt idler pulleys.
38. Remove the bolts and the LH valve cover.
39. Remove the bolts and the RH valve cover.
40. Remove the knock sensors.
41. NOTE: LH side is shown; RH side is similar.
Remove the exhaust manifold.
1 Remove the 16 nuts.
2 Remove the exhaust manifold.
3 Remove the exhaust manifold gasket.
42. Remove the four bolts.
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Part 2 Of 2:
43. Remove the engine front cover.
44. NOTE: Be careful when removing the gasket. It is reusable if not damaged.
Remove the oil pan and the gasket.
45. Remove the crankshaft position sensor pulse wheel.
46. Using the special tool, remove the 32 roller followers.
47. Remove the bolts and the RH and LH timing chain tensioners.
48. Remove the RH and LH timing chain tensioner arms.
49. Remove the RH and the LH timing chains and the crankshaft sprocket.
50. Remove the RH and LH timing chain guides.
51. Remove the RH and LH cylinder heads.
52. Remove the bolts, the oil filter adapter, and the oil gasket.
53. Clean and inspect the oil filter adapter and the oil cooler.
^ Plug the oil cooler coolant lines.
^ Flush the adapter and cooler with parts cleaner. If metal particles are present, install a new oil filter adapter and oil cooler.
54. Remove the bolts and the oil pump screen and pickup tube.
55. Remove the oil pump screen and pickup tube spacer.
56. Remove the spacers and the windage tray.
57. Remove the bolts and the LH engine mount.
58. Remove the bolts and the RH engine mount.
59. Remove the bolts and the oil pump.
60. CAUTION: Do not stamp the top of pistons, as ring land damage can occur.
NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation in the following sequence.
Remove the connecting rod caps for piston numbers 1 and 6.
^ Discard the bolts.
61. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer following manufacturer's instructions.
Using the special tool, push piston numbers 1 and 6 through the top of the cylinder block.
62. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat the previous two steps.
63. Remove the side bolts.
64. Remove and discard the bolts.
65. Remove the main bearing cap and the crankshaft lower main bearings from the cylinder block.
66. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.