Part 3

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 and crankshaft rear seal must be removed before mounting the engine on the engine stand.

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

51. Remove the bolt and the RH timing chain guide.





52. Remove the RH timing chain.





53. Remove the 2 bolts and the LH timing chain tensioner.





54. Remove the LH timing chain tensioner arm.





55. Remove the bolt and the LH timing chain guide.





56. Remove the LH timing chain.





57. Remove the crankshaft sprocket.





58. 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. Failure to follow this instruction may cause engine damage.

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

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.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.

Remove the 10 bolts and the RH cylinder head.
- Discard the cylinder head gasket.

- Discard the cylinder head bolts.






59. 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. Failure to follow this instruction may cause engine damage.

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

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.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.

Remove the 10 bolts and the LH cylinder head.
- Discard the cylinder head gasket.

- Discard the cylinder head bolts.






60. 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.

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 this procedure may cause 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.
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.


61. 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.

62. Remove the oil pump screen and pickup tube support bracket nut.





63. Remove the 2 bolts and the oil pump screen and pickup tube.





64. Remove the 2 upper bolts, the 2 lower stud bolts and the oil pump.





65. 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.

66. 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 8 connecting rod caps and bearings. Discard the bolts.






67. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow this instruction may result in engine damage.

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






68. Disassemble the 8 pistons. For additional information, refer to Piston .
- Inspect the pistons.


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





70. NOTE: Correct stud bolt location is essential for assembly procedure. Record the stud bolt location.

Remove and discard the 19 main bearing cap bolts and the stud bolt.






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





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





73. Remove the 4 bolts and the 4 piston oil cooler valves.





74. Inspect the cylinder block.