Disassembly

Engine














1. Remove the engine. For additional information, refer to Engine Removal under the Removal portion.

2. Remove the 8 bolts and the flexplate.





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





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





5. Remove the 2 rear oil pan bolts and the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.





6. NOTICE: Use care when lowering the engine to prevent damage to the oil pan.

Lower the engine onto wooden blocks.


7. Remove the Engine Lifting Bracket.





8. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.





9. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.





10. Mount the engine on a suitable work stand.

11. Remove the 4 bolts and the RH engine support insulator.





12. Remove the 4 bolts and the LH engine support insulator.





13. NOTE: LH shown, RH similar.

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

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






14. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





15. Disconnect the Camshaft Position (CMP) sensor electrical connector.





16. Disconnect the Knock Sensor (KS) electrical connector.





17. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.





19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.

20. Remove the nut and the radio frequency interference capacitor.





21. Remove the nut attaching the oil level indicator tube to the front of the engine.





22. Remove the bolt attaching the oil level indicator tube to the LH cylinder head.





23. Position the oil level indicator tube aside.





24. 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 fasteners are part of the valve cover and should not be removed.

Remove the LH valve cover.
- Fully loosen the 14 fasteners and remove the valve cover.

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

- Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.






25. 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 fasteners are part of the valve cover and should not be removed.

Remove the RH valve cover.
- Fully loosen the 14 fasteners and remove the valve cover.

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

- Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.






26. Remove the bolt and the accessory drive belt idler pulley.





27. Remove the 4 bolts and the coolant pump pulley.





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





29. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.





30. Remove the 3 bolts and the power steering pump.





31. Remove the 4 front oil pan bolts.





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

Remove the 15 fasteners.






33. Remove the engine front cover from the cylinder block.





34. Remove the crankshaft sensor ring from the crankshaft.





35. NOTICE: The balance shaft bearing caps must be installed in their original locations. Record the balance shaft bearing cap locations. Failure to follow these instructions may result in engine damage.

Remove the 6 bolts and remove the balance shaft bearing caps.






36. Remove the balance shaft.





37. Remove the 10 spark plugs.

38. NOTE: Camshaft roller follower is removed for clarity.

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






39. NOTICE: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions 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 Cylinder Head Cylinder Head.

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.

Use the Valve Spring Compressor to compress the valve springs, and remove the all of the camshaft roller followers.






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





41. 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, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.

Remove the timing chain tensioning system from both timing chains.
1. Remove the 4 bolts.

2. Remove the timing chain tensioners.

3. Remove the timing chain tensioner arms.






42. Remove the 2 timing chains and crankshaft sprocket.





43. 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.






44. Remove the RH exhaust manifold.
- Remove and discard the 10 nuts.

- Remove the RH exhaust manifold.

- Remove and discard the RH exhaust manifold gaskets.






45. Remove the LH exhaust manifold.
- Remove and discard the 10 nuts.

- Remove the LH exhaust manifold.

- Remove and discard the LH exhaust manifold gaskets.






46. NOTE: RH shown, LH similar.

Remove and discard the 20 exhaust manifold studs.






47. Clean and inspect the exhaust manifolds.

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





49. NOTICE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters.






50. Remove the insert from the LH cylinder head.





51. NOTICE: 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.

NOTICE: 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.

NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may 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 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.

NOTE: LH shown, RH similar.

Remove the 24 bolts and the cylinder heads.
- Discard the cylinder head gasket.

- Discard the cylinder head bolts.






52. 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: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow these instructions may result in engine damage.

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.


53. 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.





54. Remove the 4 bolts, the nut, the oil filter adapter and discard the gasket.





55. Clean the oil filter adapter gasket surface at the cylinder block.





56. Remove the 4 coolant pump bolts and the coolant pump.
- Discard the O-ring seal.






57. 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's instructions.

58. Remove the 14 bolts, the oil pan and the oil pan gasket.
- Discard the oil pan gasket.






59. Remove the 3 bolts, the oil pump screen cover and tube and the spacer.





60. Remove the 3 bolts and the oil pump.





61. NOTICE: Make sure connecting rods and rod caps are numbered to keep them in the correct orientation. Failure to follow these instructions may result in engine damage.

Remove the 20 bolts and the connecting rod caps.
- Rotate the crankshaft so that the connecting rod is at bottom dead center.

- Remove and discard the bolts.






62. NOTICE: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. Failure to follow these instructions may result in cylinder block damage.

Remove the piston and rod assembly.
- Using the Connecting Rod Installer, guide the piston and rod assembly out of the cylinder.






63. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.

64. Disassemble the 10 pistons. For additional information, refer to Piston Piston.

65. Remove and discard the 12 cross-mounted bolts.





66. Remove and discard the 12 bolts.





67. Remove the 12 main bearing cap dowel pins.





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





69. Remove the crankshaft and the crankshaft main bearings from the cylinder block.