Disassembly

DISASSEMBLY

Engine

Special Tools And Equipment:

Special Tool(s)

Disassembly

Vehicles equipped with a manual transmission






1. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release.

NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.

Remove the bolts, the clutch pressure plate and the clutch disc.

All vehicles





2. Remove the flywheel or flexplate.
3. Remove the engine-to-transmission spacer plate.
4. Mount the engine to a suitable engine stand and remove the lifting equipment and Lifting Eyes.






5. CAUTION: Do not pull on the spark plug wires. Twist the boot while pulling upwards.

Disconnect the spark plug wires.





6. Disconnect the ignition coil electrical connector.





7. Remove the bolts and the ignition coil assembly.





8. Remove the bolts and the generator mounting bracket.





9. Remove the four bolts and the coolant pump pulley.





10. Remove the bolts and the crankshaft pulley.





11. Remove the crankshaft damper bolt.





12. Using a Crankshaft Vibration Damper Remover, remove the crankshaft damper.





13. Disconnect the engine control sensor wiring from:
^ the Engine Coolant Temperature (ECT) sensor.
^ the water temperature indicator sender unit.
^ the fuel injectors.
^ the Camshaft Position (CMP) sensor.






14. NOTE: To prevent stretching the valve cover gasket, loosen silicone gasket and sealant from the cylinder head by sliding a flat knife between the valve cover gasket and cylinder head.

Remove the valve covers.





15. If necessary, remove the valve cover gaskets.





16. Clean the sealing surfaces.





17. Remove the rocker arms and the push rods.





18. Remove the lower intake manifold.
^ Remove the eight bolts.
^ Remove the lower intake manifold.





19. Remove and discard the intake manifold gaskets and end seals.





20. Clean the sealing surfaces.





21. Remove the screws and the Camshaft Position (CMP) sensor.





22. Remove the camshaft synchronizer bolt.






23. NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.

Remove the camshaft synchronizer.





24. Remove the oil pan.
^ Remove the bolts.





25. Remove the oil pan baffle.





26. Remove the oil pan gasket.





27. Clean the surfaces.





28. Remove the Crankshaft Position (CKP) sensor.





29. Remove the engine front cover.
^ Remove the ten bolts.





30. Remove the engine front cover gasket.





31. Clean the sealing surfaces.





32. Remove the oil level indicator tube.





33. Remove the oil filter.





34. Remove the bolts.





35. Remove the cylinder heads.





36. Remove the head gaskets.





37. Remove the valve tappet guide plate retainer.





38. Remove the valve tappet guide plates.






39. NOTE: The valve tappets are positional. Identify each valve tappet for installation in the Original position.

Remove the valve tappets.





40. Align the timing marks.





41. Remove the bolt.





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





43. Remove the camshaft retainer.





44. Remove the camshaft.





45. If required, remove the camshaft bearings.
^ Use the Camshaft Service Set.





46. Remove the oil pump.






47. NOTE: Before removing the piston and connecting rod assemblies, inspect the top of the cylinder bores. If necessary 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.





48. Remove the bolts.





49. Remove the main bearing caps.





50. Remove the lower crankshaft main bearings.





51. Remove the crankshaft rear oil seal.





52. Remove the crankshaft.





53. Remove the crankshaft upper main bearings.