Engine - Disassembly

Engine













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

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

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

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

1. Remove the bolts and the flexplate.





2. Remove the spacer plate.





3. Using the Crankshaft Rear Oil Slinger Remover and the Slide Hammer, remove the crankshaft rear oil slinger.





4. Using the Crankshaft Rear Oil Seal Remover and the Slide Hammer, remove the crankshaft rear seal.





5. Remove the 16 bolts, oil pan and oil pan gasket.
- Discard the oil pan gasket.

- Clean and inspect the sealing surfaces.





6. Remove the 6 bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.





7. Mount the engine on a suitable workstand.

8. Remove the 3 bolts and the RH engine support insulator.





9. NOTE: LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.





10. NOTE: LH shown, RH similar.

If equipped, install the cylinder block drain plugs.

- Tighten to 24 Nm (18 lb-ft).





11. Remove the nut and position the electronic cooling fan clutch wiring harness aside.





12. NOTICE: Do not sideload the cooling fan clutch coil or the cooling fan clutch may be damaged.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan assembly.





13. Release the clamp and remove the lower radiator hose.





14. NOTE: RH shown, LH similar.

Remove the nuts and the 2 radio interference capacitors.





15. Remove the bolt and the Camshaft Position (CMP) sensor.





16. Remove the bolt and the Crankshaft Position (CKP) sensor.





17. NOTICE: 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.

NOTE: LH shown, RH similar.

Remove the valve covers.
- Fully loosen the 22 fasteners and remove the valve covers.

- Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.





18. Remove the 7 bolts, the coolant pump pulley and the accessory drive belt idler pulleys.





19. Remove the 4 bolts.





20. Remove the coolant pump from the cylinder block.





21. Remove the 3 bolts and the accessory drive belt tensioner.





22. Remove the crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.

23. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.





24. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft seal.





25. Remove the 4 oil pan-to-engine front cover bolts.





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

Remove the 15 engine front cover fasteners.





27. NOTICE: 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.

Remove the engine front cover from the front cover-to-cylinder block dowel.

- Remove the engine front cover gaskets.

- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the mating surfaces.





28. NOTICE: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

Remove the 8 spark plugs.

29. NOTE: Camshaft roller follower is removed from art for clarity.

Install the Valve Spring Compressor Spacer, between the valve spring coils to prevent valve stem seal damage.





30. NOTICE: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow this instruction may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Engine Engine - Removal.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.

Using the Valve Spring Compressor, compress the valve springs and remove the camshaft roller followers.





31. Repeat the previous 2 steps for each of the roller followers.

32. Remove the crankshaft sensor ring from the crankshaft.





33. Position the crankshaft with the keyway at the 12 o'clock position.





34. NOTICE: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.

Remove the timing chain tensioning system from both timing chains.

1. Remove the 4 bolts.

2. Remove the 2 timing chain tensioners.

3. Remove the 2 timing chain tensioner arms.





35. Remove the 2 timing chains and the crankshaft sprocket.





36. Remove the timing chain guides.

1. Remove the 2 bolts.

2. Remove the LH timing chain guide.

3. Remove the 2 bolts.

4. Remove the RH timing chain guide.





37. Remove the 2 bolts and the RH exhaust manifold heat shield.





38. Remove the RH exhaust manifold.

1. Remove and discard the 8 nuts.

2. Remove the RH exhaust manifold.

3. Remove and discard the RH exhaust manifold gasket.





39. Remove the LH exhaust manifold.

1. Remove and discard the 8 nuts.

2. Remove the LH exhaust manifold.

3. Remove and discard the 2 LH exhaust manifold gaskets.





40. NOTE: RH shown, LH similar.

Remove and discard the 16 exhaust manifold-to-cylinder head studs.





41. Clean and inspect the exhaust manifolds.

42. Remove the bolt and the oil level indicator tube.





43. Remove the insert from the LH cylinder head.





44. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.





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

NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

NOTICE: 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.

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

NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTE: RH shown, LH similar.

Remove the 20 bolts and the cylinder heads.
- Discard the cylinder head gaskets.

- Discard the cylinder head bolts.





46. NOTICE: 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: 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 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.

47. NOTE: LH shown, RH similar.

Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.





48. Remove the 3 bolts and the LH engine support insulator.





49. Remove and discard the oil filter. Remove the 4 bolts and the oil filter adapter.





50. Clean the gasket surfaces at the cylinder block and the oil filter adapter.





51. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.





52. Remove the 3 bolts and the oil pump.





53. 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.

54. NOTICE: 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 16 bolts and the connecting rod caps. Discard the bolts.





55. NOTICE: Remove the piston and connecting rod assemblies carefully, or the cylinder walls or crankshaft journals may be damaged.

Use the Connecting Rod Installer to push the piston through the top of the cylinder block.





56. Disassemble the 8 pistons. For additional information, refer to Piston Piston - Disassembly and Assembly.

57. NOTE: Note the location of the main bearing cap stud bolt for assembly reference.

Remove the 20 fasteners.

1. Remove and discard the 10 cross-mounted main cap bolts.

2. Loosen the 10 jack screws.

3. Remove and discard the 9 main bearing cap bolts and the stud bolt.





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





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