Disassembly

1. With the engine mounted on a work stand, remove the left and right valve covers and discard the gaskets.

NOTE: Before starting disassembly, remove all wiring harnesses, emission control system, fuel system, ignition system, flywheel, engine rear plate and front end accessory drive Components. All valve train components should be identified to make sure they are installed in their original positions during assembly.

2. Remove the upper and lower intake manifold assemblies.
3. Remove the oil level dipstick and oil level indicator tube assembly and remove the oil filter.





4. Remove the rocker arms, rocker arm seats, push rods, rocker arm fulcrum guides and valve tappets and remove the cylinder heads.
5. Remove the crankshaft pulley and crankshaft vibration damper/pulse ring.
6. Remove the water pump and engine front cover as an assembly. Discard the gasket and seal.
7. Remove the oil pan and discard the gasket.





8. Remove the oil pump, oil pump screen cover and tube assembly and oil pump intermediate shaft.
9. Remove the crankshaft rear oil seal.








10. Remove the camshaft sprocket, capscrew, washer and eccentric or timing flag. Slide the sprocket and timing chain forward and remove the timing chain and sprocket as an assembly.
11. Remove the camshaft thrust plate and remove the camshaft.
12. Remove the connecting rod caps and remove the piston.

NOTE: Pistons, connecting rods and bearings should be numbered to make sure they are assembled in their original positions. 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.

13. Remove the crankshaft main bearing caps, crankshaft main bearings and crankshaft.

CAUTION: When removing the crankshaft, take care not to damage any of the bearing surfaces on the crankshaft.

NOTE: The location of the main bearing caps and the main bearing inserts should be identified. When the engine is assembled, crankshaft main bearings which are to be reused should be installed in their original positions.

14. For cleaning purposes, the oil gallery and coolant drain plugs can be removed.