Part 3

Engine











Disassembly (Steps 55-81)

55. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.

Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
^ Discard the VCT phaser sprocket bolt.





56. Install the special tool onto the LH cylinder head.





57. Install the special tool onto the RH cylinder head.





58. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.

Remove the 2 bolts and the RH front camshaft bearing cap.





59. CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the remaining RH camshaft bearing caps.





60. Clean and inspect the RH camshaft bearing caps.
^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.





61. Remove the RH camshaft.

62. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.

Remove the remaining camshaft roller followers from the RH cylinder head.

63. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the RH cylinder head.

64. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.

Remove the 2 bolts and the LH front camshaft bearing cap.





65. CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the remaining LH camshaft bearing caps.





66. Clean and inspect the LH camshaft bearing caps.
^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.





67. Remove the LH camshaft.

68. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.

Remove the remaining camshaft roller followers from the LH cylinder head.

69. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the LH cylinder head.

70. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Failure to follow these instructions may result in engine damage.

CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.

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

NOTE: RH shown, LH similar.

Remove the bolts and the cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.





71. 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.

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 head and the cylinder block in the following sequence.
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 surfaces is normal.

72. 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 within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

NOTE: LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the 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 in) across a 38.1 mm (1.5 in) square area, or scratches longer than 0.0254 mm (0.001 in).





73. Remove the bolts, the oil pump screen and pickup tube and the spacer.





74. Remove the 3 bolts and the oil pump.





75. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer instructions.

76. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation. Failure to follow these instructions may result in engine damage.

Remove the bolts and the connecting rod caps. Discard the bolts.





77. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Use the special tool to push the piston through the top of the cylinder block.





78. Disassemble the 8 pistons.
79. Remove the fasteners.
1 Remove and discard the cross-mounted main cap bolts.
2 Remove the dowels.
3 Remove and discard the main bearing cap bolts.





80. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.





81. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.