Disassembly

Engine








Special Tool(s)

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: The crankshaft rear seal, the oil seal slinger and the seal retainer plate must be removed before mounting the engine on the engine stand.





1. Remove the flexplate.





2. Using the special tools, remove the crankshaft oil slinger.





3. Using the special tools, remove the crankshaft rear seal.





4. Remove the bolts and the crankshaft rear seal retainer plate.
5. Place the engine on a suitable engine stand.
6. Remove the Modular Engine Lift Bracket.





7. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





8. Disconnect the Camshaft Position (CMP) electrical connector.





9. Disconnect the RH radio frequency interference capacitor electrical connector.





10. Disconnect the knock sensor electrical connector.





11. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





12. Disconnect the oil pressure switch electrical connector.
13. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.





14. Remove the crankcase ventilation tube from the LH valve cover.





15. Remove the Positive Crankcase Ventilation (PCV) valve and hose from the RH valve cover.





16. Remove the bolts, the oil pan, and the oil pan gasket.





17. Remove the two bolts, the nut, the oil pump screen cover and tube, and the spacer.





18. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: The bolts are part of the valve cover and should not be removed.

Remove the LH valve cover.
^ Fully loosen the bolts and remove the valve cover.
^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





19. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: The bolts are part of the valve cover and should not be removed.

Remove the RH valve cover.
^ Fully loosen the bolts and remove the valve cover.
^ Clean the valve cover mating surfaces of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





20. Remove the water pump pulley.
1 Remove the bolts.
2 Remove the water pump pulley.





21. Remove the water pump bolts.





22. Remove the water pump from the cylinder block.





23. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.





24. Using the special tool, remove the crankshaft front seal.





25. Remove the bolt and the belt idler pulley.





26. Remove the four oil pan bolts.





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

Remove the fasteners.





28. Remove the engine front cover from the front cover-to-cylinder block dowels.
29. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.





30. Install the special tool between the valve spring coils to prevent valve stem seal damage.





31. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.

Use the special tool to compress the valve springs, and remove the camshaft roller followers.





32. Remove the special tool.





33. Remove the crankshaft sensor ring from the crankshaft.








34. CAUTION: The bearing caps must be marked for installation in their original location or engine damage can occur.

Remove the six bolts, the bearing caps and the balance shaft.





35. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts 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 keyway at the 12 o'clock position.





36. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins.





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

Remove the LH and RH timing chain and the crankshaft sprocket.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Remove the LH timing chain from the camshaft sprocket.
^ Remove the LH timing chain and the crankshaft sprocket.





38. Remove the timing chain guides.
^ Remove the bolts.
^ Remove the timing chain guides.





39. Remove the 10 nuts and the RH exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket.





40. Remove the 10 nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.





41. Remove the oil level indicator, the bolt and the oil level indicator tube.





42. Install the special tools on both ends of the cylinder head.





43. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. 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.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.

NOTE: LH shown; RH similar.

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

44. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3 Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4 Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surface is normal.





45. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat with 0.010 mm (0.0004 inch) from end to end.

NOTE: LH is shown, RH is similar.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the cylinder head deck face and the cylinder block deck face with a straightedge, paying particular attention to the oil pressure feed area. 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).





46. Remove the bolts and the engine mounts.





47. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.





48. Remove the bolts and the oil pump.





49. CAUTION: Make sure connecting rods and rod caps are numbered, to retain correct orientation.

Remove the bolts and the connecting rod caps.
^ Rotate the crankshaft so that the connecting rod is at bottom dead center.
^ Remove and discard the bolts.





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

Remove the piston and rod assembly.
^ Using the special tools, guide the piston and rod assembly out of the cylinder.
51. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.





52. Remove and discard the 12 cross-mounted bolts.





53. Remove and discard the bolts.





54. Remove the main bearing cap dowel pins.





55. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.





56. Remove the crankshaft and the crankshaft main bearings from the cylinder block.