Part 2
EngineDisassembly (Steps 28-54)
28. Detach the wire retainer from the TP sensor stud bolt.
29. Loosen the nut and remove the EGR system module-to-exhaust manifold tube.
30. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.
31. Remove the 3 bolts and the ignition coil.
32. Disconnect the vacuum harness connection and remove the vacuum harness from the engine.
33. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.
34. Remove the upper intake manifold and discard the gaskets.
35. Remove the bolts and the fuel rail, fuel injectors and fuel charging harness as an assembly.
36. Remove the fuel injector clips and fuel injectors.
37. Remove and discard the fuel injector O-rings.
38. NOTE: Record the location of the 6 long bolts and the 8 short bolts.
Remove the bolts and the lower intake manifold assembly.
39. Remove and discard the lower intake manifold sealing components.
40. Remove the 3 nuts and the heat shield.
41. Remove the 6 nuts and the RH exhaust manifold.
42. Remove the 6 nuts and the LH exhaust manifold.
43. Clean and inspect the exhaust manifolds.
44. Remove the LH valve cover.
1 Remove the 3 bolts.
2 Remove the 2 stud bolts.
3 Remove the LH valve cover.
45. Remove the RH valve cover.
1 Remove the 3 stud bolts.
2 Remove the 2 bolts.
3 Remove the RH valve cover.
CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
46. NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.
Remove the rocker arms.
1 Remove the bolts.
2 Remove the rocker arms and pivots.
47. NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.
Remove the 12 push rods.
48. Remove the lower 3 exhaust manifold studs from both cylinder heads.
49. NOTE: Record the location of long and short bolts.
Remove and discard all the cylinder head bolts.
50. NOTE: RH shown, LH similar.
Remove the RH and LH cylinder heads and the gaskets. Discard the gasket.
51. 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 that 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 the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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 surfaces is normal.
52. Inspect the cylinder heads for distortion.
53. Remove and discard the engine oil filter.
54. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, remove the oil cooler and tube assembly bolt.
^ Discard the oil cooler and tube assembly.
