Disassembly

Special Tools:

1. Disconnect the vacuum harness.





2. Remove the vacuum harness.
- Disconnect the vacuum harness.
- Remove the vacuum harness.





3. Disconnect the connectors.
- Disconnect the idle air control (IAC)
- Disconnect the throttle position (TP) sensor.
- Disconnect the differential feedback EGR.





4. Disconnect the connectors.
- Disconnect the camshaft position (CMP) sensor.
- Disconnect the engine coolant temperature sensor.

5. Disconnect the oil pressure switch.
6. Remove the generator and the generator mounting bracket.
7. Remove the air conditioning compressor and bracket.
8. Remove the power steering pump and the power steering pump bracket.





9. Remove the water pump pulley.
- Remove the bolts.
- Remove the pulley.





10. Remove the crankshaft pulley.
- Remove the bolts.
- Remove the pulley.





11. Remove the damper bolt.





12. Using the special tool, remove the crankshaft damper.





13. Remove the bracket bolt.





14. Remove the EGR valve. Loosen the nut.
- Remove the bolts.
- Remove the valve.





15. Disconnect the PCV valve and hose.





16. Remove the upper intake manifold.
- Remove the six bolts.
- Remove the manifold.





17. Remove the intake manifold gasket.





18. Disconnect the fuel injector harness.





19. Disconnect the crankshaft position (CKP) sensor.





20. Remove the fuel charging wee harness





21. Remove the spark plug wire retainers.





22. Remove the ignition coil and spark plug wires as an assembly.
- Remove the bolts.
- Remove the coil and wires.





23. Remove the valve covers.





24. If required, remove the valve cover gaskets.





25. Remove the fuel injection manifold and fuel injectors as an assembly.
- Remove the four bolts.
- Remove the manifold and injectors.





26. Remove the rocker arms and the push rods.





27. Remove the lower intake manifold.
- Remove the bolts.
- Remove the lower intake manifold.





28. Remove the intake manifold gaskets and the end seals.





29. Remove the valve tappet guide plate retainer.





30. Remove the valve tappet guide plates.





31. Note: The valve tappets are positional. Identify each valve tappet for the installation in the original position.

Remove the valve tappets.
32. Remove the camshaft synchronizer.





33. Remove the bolts.





34. Remove the oil pan.





35. Remove the oil pan gasket.





36. Remove the crankshaft position (CKP) sensor.





37. Remove the engine front cover and bolts.





38. Remove the engine front cover and the engine front cover gasket.





39. Remove the EGR valve to exhaust manifold tube.





40. Remove the oil level indicator tube.





41. Remove the LH exhaust manifold
- Remove the six bolts.
- Remove the manifold.
- Remove the manifold gasket.





42. Remove the RH exhaust manifold.
- Remove the six bolts.
- Remove the manifold.
- Remove the manifold gasket.





43. Remove the oil bypass filter.





44. Remove the eight cylinder head bolts.





45. Remove the cylinder heads.





46. Remove the head gaskets.





47. Align the timing marks.





48. Remove the camshaft sprocket bolt.





49. Remove the timing sprockets and the timing chain as an assembly.





50. Remove the camshaft thrust: plate.
- Remove the bolts.
- Remove the thrust plate.





51. Remove the camshaft.





52. If required, remove the camshaft bearings.





53. Remove the oil pump.
- Remove the bolt.





54. Note: Before removing the piston and connecting rod assemblies, inspect the top of the cylinder bores. If required, remove the cylinder ridge.

Remove the piston and connecting rod assemblies one at a time.
- Remove the connecting rod nuts in pairs.
- Remove the connecting rod cap.
- Remove the piston and connecting rod assembly.





55. Remove the main bearing cap bolts.





56. Remove the main bearing caps.





57. Remove the lower crankshaft main bearings.





58. Remove the crankshaft rear oil seal.





59. Remove the crankshaft.





60. Remove the upper crankshaft main bearings.
61. Clean all mating and sealing surfaces of old gasket material and debris.