Engine - Disassembly

Engine









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.

NOTE: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

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

Vehicles with manual transmission

1. NOTICE: 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 6 bolts, the clutch pressure plate and the clutch disc.





All vehicles

2. Using the Flywheel Locking Tool, remove the 6 bolts and the flexplate or flywheel.





3. Mount the engine on a suitable engine stand.

4. Remove the drive belt.





5. Remove the engine oil level indicator, the 2 bolts and the engine oil level indicator tube.





6. Remove the 2 bolts and the front coolant outlet pipe.





7. Remove the 4 bolts and the A/C compressor.





8. NOTE: The generator will be removed with the accessory bracket.

Remove the 5 bolts and the accessory bracket and generator as an assembly.





9. Remove the 4 bolts and the RH engine mount bracket.





10. Disconnect the coolant hose assembly from the thermostat housing and the PCV fitting on the intake manifold.





11. Remove the 2 nuts and the coolant tube assembly.





12. Remove the 7 nuts, the exhaust manifold and gasket.
- Discard the 7 nuts and the exhaust manifold gasket.





13. Remove and discard the 7 exhaust manifold-to-cylinder head studs.

14. Clean and inspect the exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.

15. If equipped, remove the block heater.





16. Remove the rear coolant outlet pipe.

1. Disconnect the coolant hose.

2. Remove the 4 bolts, the rear coolant outlet pipe and discard the gasket.





17. Remove the EGR valve.

1. Disconnect the electrical connector.

2. Disconnect the coolant hose.

3. Remove the 2 bolts, the EGR valve and discard the gasket.





18. Remove the 4 bolts and the power steering pump.





19. Disconnect the Idle Air Control (IAC) valve, the Throttle Position (TP) sensor and the Manifold Absolute Pressure (MAP) sensor electrical connectors.





20. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.





21. Disconnect the Knock Sensor (KS) electrical connector, remove the 3 bolts and position the engine wiring harness and bracket aside.





22. Disconnect the Camshaft Position (CMP) sensor electrical connector and the PCV hose.





23. Disconnect the engine wiring harness pin-type retainers from the intake manifold.

24. Remove the 2 bolts and the EGR tube from the intake manifold.





25. Remove the EGR tube.
- Remove the EGR tube bracket bolt from the intake manifold.

- Disconnect the EGR tube from the cylinder head.

- Remove the EGR tube.





26. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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 5 bolts and the intake manifold.

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





27. Disconnect the 4 fuel injector electrical connectors and the 2 wiring harness pin-type retainers.





28. Disconnect the ignition coil and the Cylinder Head Temperature (CHT) sensor electrical connectors.





29. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.





30. NOTICE: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. Failure to follow this instruction may result in poor engine performance.

NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

With a twisting motion, disconnect the spark plug wires from the spark plugs.

31. Remove the 4 bolts and the ignition coil.





32. Remove the 3 bolts and the thermostat housing.





33. Remove the 9 bolts, the KS and the engine vent cover.





34. Remove the 4 bolts and the LH engine mount bracket.





35. Remove the 2 bolts, fuel rail with the injectors and the ground strap.
- Discard the fuel injector O-ring seals.





36. Remove the 3 bolts and the coolant pump pulley.





37. Remove the 3 bolts and the coolant pump.
- Discard the O-ring seal.





38. Remove the CMP sensor, CHT sensor and the spark plugs.





39. Remove the 14 fasteners and the valve cover.





40. Remove the 2 bolts and discard the CKP sensor.





41. NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine.

NOTICE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).





42. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.

NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.





43. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

- Remove and discard the crankshaft pulley bolt and washer.

- Remove the crankshaft pulley.

- Remove the diamond washer and discard.





44. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the Oil Seal Remover, remove the crankshaft front oil seal.





45. NOTE: There is one engine front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.

Remove the 20 bolts, the stud bolt and the engine front cover.





46. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.

2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.

3. Insert a paper clip into the hole to retain the tensioner.





47. Remove the 2 bolts and the timing chain tensioner.





48. Remove the RH timing chain guide.





49. Remove the timing chain.





50. Remove the 2 bolts and the LH timing chain guide.





51. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft may occur.

NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.

Remove the 2 bolts, 2 washers and camshaft drive sprockets.





52. Remove the oil pump chain drive tensioner.

1. Release the tension on the tensioner spring.

2. Remove the 2 shoulder bolts and the tensioner.





53. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.

Remove the bolt, the chain, sprockets and diamond washers.





54. Remove the Camshaft Alignment Plate.





55. NOTICE: Failure to follow the camshaft loosening procedure may result in damage to the camshafts.

NOTE: Mark the location and orientation of each camshaft bearing cap.

NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.

Remove the camshaft bearing caps.

- Loosen the 20 camshaft bearing cap bolts in sequence shown, one turn at a time.

- Repeat the first step until all tension is released from the camshaft bearing caps.

- Remove the camshaft bearing caps.





56. Remove the camshafts.

57. 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. Foreign material, including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.

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 torque-to-yield designed and cannot be reused.

Remove the 10 bolts and the cylinder head.

- Discard the cylinder head bolts.





58. Remove and discard the cylinder head gasket.

59. Remove the cylinder head alignment dowels.





60. Remove the 13 bolts and the oil pan.





61. Remove the 6 bolts and the rear crankshaft seal and retainer plate.
- Discard the crankshaft rear seal and retainer plate assembly.





62. Remove the 4 bolts, the oil pump pickup tube and discard the gasket.





63. Remove the 4 bolts and the oil pump assembly.
- Discard the gasket.





64. 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 manufacturer's instructions.

65. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

Remove the connecting rod cap bolts and cap.





66. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.

- Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.





67. Remove the bolts in the sequence shown.
- Remove the main bearing beam.

- Discard the bolts.





68. Remove the crankshaft from the engine block.





69. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

Remove the main bearings from the main bearing beam.





70. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

NOTE: The center bulkhead has the thrust bearing.

Remove the main bearings from the cylinder block.





71. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.

NOTE: The front bulkhead does not have an oil squirter.

Remove the 4 oil squirters.





72. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to Engine System - General Information Procedures.