Part 2 of 2

Engine Disassembly Continued (Part 2 of 2)

45. NOTE: RH shown, LH similar.





Remove the studs and the RH and LH valve cover.
^ Remove and discard the gaskets.





46. Remove the bolt and stud and the coolant tube.





47. Remove the bolts and studs and the oil pan.
^ Discard the gasket.





48. Remove the bolts, nut and the oil pick-up tube and screen.





49. Remove the nuts and the oil pan baffle.





50. Remove and discard the oil filter.





51. Remove the stud and the oil level indicator and tube





52. Remove the oil pressure sensor.





53. Remove the bolts, studs and the front cover.
^ Remove and discard the front cover gaskets.





54. Remove the crankshaft front seal from the front cover and discard.

55. CAUTION: This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30 RFF" only (orange in color).





Remove the ignition pulse wheel.





56. Install the damper bolt.

57. NOTE: LH shown, RH similar.





Remove the LH and RH spark plugs.





58. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).
^ Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.





59. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the NEUTRAL position.





60. Verify that the RH camshafts are in the neutral position.





61. Remove the RH timing chain tensioner arm.
1 Remove the bolts.
2 Remove the tensioner.
3 Remove the tensioner arm.





62. Remove the bolts, RH timing chain guide and the timing chain.





63. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the NEUTRAL position.





64. Verify the LH camshafts are in the neutral position.





65. Remove the LH timing chain and tensioner arm.
1 Remove the bolts.
2 Remove the tensioner.
3 Remove the tensioner arm.





66. Remove the LH timing chain and timing chain guide.





67. Remove the damper bolt and the crankshaft sprockets.

68. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 inch) past flush of the end of the camshaft. The service pulley gets pressed on flush to the end of the camshaft.





Using the special tools, remove the coolant pump drive pulley and discard.

69. NOTE: In order to make sure of correct sealing, do not scratch the camshaft.





Using the special tools, remove the camshaft oil seal and discard.





70. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.

71. CAUTION: Record camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.





Loosen the LH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
^ Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.

72. CAUTION: Record camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.





Loosen the RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
^ Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
73. Remove the LH and RH camshafts.

74. CAUTION: The camshaft followers must be installed in their original position.

NOTE: LH shown, RH similar.





Remove the LH and RH camshaft followers.
^ Mark the location of the followers using a permanent-type marker.

75. NOTE: LH shown, RH similar.





Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
^ Discard the gaskets.

76. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. 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) deep.





77. Remove the bolts and the crankcase cover.
^ Discard the gasket.





78. Remove the bolts in the indicated sequence and remove the oil pump.





79. Remove the connecting rod cap bolts. Hold the piston rod assembly to keep it from falling from the engine block.





80. Using the special tool, remove the piston rod assembly from the engine block.
81. Remove the engine block from the stand and place on a workbench.





82. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.





83. Remove the crankshaft rear main seal and remove the crankshaft.





84. Remove the crankshaft key.





85. Remove the crankshaft thrust bearing from the cylinder block.





86. Remove the bearings from the lower cylinder block.





87. Remove the crankshaft main bearings from the cylinder block.
88. Inspect the cylinder block, lower cylinder block, pistons and connecting rods.