Part 2

Items 65-67: Crankshaft Pulley Disassembly Note





1. Remove the bolt and washer.
^ Discard the bolt and washer.





2. Using the special tool, remove the crankshaft damper.

Item 68: Crankshaft Front Seal Disassembly Note





1. Using the special tool, remove the crankshaft front seal.
^ Discard the seal.

Item 74: Fuel Charge Manifold Disassembly Note





1. NOTE: RH is shown, LH is similar. Remove the nut and the radio interference capacitor.

Items 79-81: Intake Manifold Disassembly Note





1. Disconnect and remove the throttle body heater hoses.





2. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.

Remove the bolts and studs in the sequence shown.
3. Remove the intake manifold.





4. 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, which make leak paths. Use a plastic scraping tool to clean the surfaces.

Clean the sealing surfaces.

Items 83-85: RH Valve Cover Disassembly Note





1. Remove the bolts in the sequence shown and remove the RH valve cover.

Items 87-89: LH Valve Cover Disassembly Note





1. Remove the bolts in the sequence shown and remove the LH valve cover.

Items 112 and 113: Engine Front Cover Disassembly Note





1. Remove the engine front cover.
^ Remove the bolts in the sequence shown.
^ Remove the engine front cover.





2. 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the sealing surfaces.

Item 114: Sump Body Assembly Disassembly Note





1. CAUTION: Use only hand tools to remove the oil pump screen and tube.

Remove the oil pump screen and tube, and the seal.





2. Remove the four bolts and the oil pump.
^ Discard the gasket.





3. 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, which make leak paths. Use a plastic scraping tool to remove all traces of the sealant.

Remove the bolts in the sequence shown and remove the sump body.

Items 121-139, 141-146, 148: Timing Drive Components Disassembly Note
1. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.





2. Make sure the flats of the camshaft are facing upward. If not, repeat Step 1.





3. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the RH cylinder head.





4. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the exhaust camshaft sprocket bolt.





5. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the variable camshaft timing (VCT) unit bolt.





6. Remove the RH timing chain tensioner.
1. Push the lever down and install a drill rod to lock the piston.
2. Remove the bolts and the tensioner.





7. Remove the tensioner arm.





8. Remove the timing chain guide.





9. Remove the RH primary timing chain.





10. Remove the special tool from the RH head.





11. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the LH head.





12. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.

Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.





13. Remove the LH timing chain tensioner.
1. Push the lever down and install a drill rod to lock the piston.
2. Remove the bolts and the tensioner.





14. Remove the tensioner arm.





15. Remove the timing chain guide.





16. Remove the LH primary timing chain.





17. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.





18. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.





19. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.





20. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Items 150-165: RH and LH Camshaft Disassembly Note

1. CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.

CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.

Record the camshaft component locations prior to removal.

Items 166-167 and 169-170: RH and LH Cylinder Head Disassembly Note





1. NOTE: LH shown, RH similar.

Remove the LH and RH cylinder head end bolts.
^ Discard the bolts.





2. Remove the bolts from both cylinder heads in the sequence shown.
^ Discard the bolts.





3. Remove the cylinder heads.
^ Discard the gaskets.





4. 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the sealing surfaces.





5. Remove the bolts and the knock sensors.