Part 2

ENGINE DISASSEMBLY - 3.0L

CAUTION:Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
14. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.





15. Remove the 5 coolant pump housing bolts.





16. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.





17. Remove the nut and the radio interference capacitor.





18. Remove the bolts and the RH valve cover.

- Discard the gasket.





19. Remove the bolts and the LH valve cover.

- Discard the gasket.





20. Remove the 15 bolts and the oil pan.

- Discard the gasket.





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





22. Remove and discard the O-ring seal.





23. Remove the oil pan baffle.
a. Remove the 4 M6 oil pan baffle nuts.

b. Remove the 4 M8 oil pan baffle nuts.





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





25. Remove the crankshaft pulley bolt and washer.

- Discard the crankshaft pulley bolt.





26. Using the 3 Jaw Puller, remove the crankshaft pulley.





27. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





NOTE:Note the position of the alignment dowel on the engine front cover.
28. Remove the 2 bolts and the LH VCT.





NOTE:Note the position of the alignment dowel on the engine front cover.
29. Remove the 2 bolts and the RH VCT.





CAUTION:Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE:Note the location of all bolts and stud bolts for installation.
30. Remove the 14 bolts, 2 stud bolts and the engine front cover.

- Discard the gaskets.





CAUTION:Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE:LH shown, RH similar.
31. Remove the LH and RH spark plugs.





NOTE:This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
32. Remove the ignition pulse wheel.





33. Install the crankshaft pulley bolt and washer.





34. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC).

- Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.





35. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.





36. Verify that the RH camshafts are in the neutral position.





37. Remove the RH timing chain tensioner arm.
a. Remove the 2 bolts.

b. Remove the tensioner.

c. Remove the tensioner arm.





38. Remove the 2 bolts and the RH timing chain guide.

- Remove the RH timing chain from the engine.





39. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.





40. Verify the LH camshafts are in the neutral position.





41. Remove the LH timing chain and tensioner arm.
a. Remove the 2 bolts.

b. Remove the tensioner.

c. Remove the tensioner arm.





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

- Remove the LH timing chain from the engine.





43. Remove the crankshaft pulley bolt and the crankshaft sprocket.





44. Remove the 4 bolts in the sequence shown.

- Remove the oil pump.





CAUTION:Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
45. Using the Oil Seal Remover, remove the camshaft oil seal and discard.





46. Remove the 2 bolts and the camshaft oil seal retainer.

- Discard the press-in-place gasket.





CAUTION:The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
47. Verify the LH camshafts are in the neutral position.





CAUTION:Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE:Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
48. Remove the 3 bolts and the LH camshaft phaser and sprocket.





49. Remove and discard the VCT system oil filter screen from the LH camshaft.





CAUTION:Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
50. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.





CAUTION:After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
NOTE:Make sure the camshaft bearing caps are marked as instructed in the previous step.
51. Loosen the bolts evenly in the sequence shown.
a. Remove the camshaft bearing thrust caps (1L and 5L).

b. Remove the remaining camshaft bearing caps.

c. Remove the camshafts from the cylinder head.





CAUTION:The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
52. Verify the RH camshafts are in the neutral position.





CAUTION:Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE:Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
53. Remove the 3 bolts and the RH camshaft phaser and sprocket.





54. Remove and discard the VCT system oil filter screen from the RH camshaft.





CAUTION:Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
55. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.





CAUTION:After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
NOTE:Make sure the camshaft bearing caps are marked as instructed in the previous step.
56. Loosen the bolts evenly in the sequence shown.
a. Remove the camshaft bearing thrust caps (5R and 1R).

b. Remove the remaining camshaft bearing caps.

c. Remove the camshafts from the cylinder head.





CAUTION:The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE:RH shown, LH similar.
57. Remove the LH and RH camshaft roller followers.

- Mark the location of the roller followers, using a permanent-type marker.

CAUTION:The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
58. Remove the hydraulic lash adjusters.





NOTE:RH shown, LH similar.
59. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.

- Discard the bolts and the gaskets.

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.
60. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.

61. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. See Cylinder Head Distortion Check and Cylinder Block Distortion Check.





62. Remove the bolts and the oil separator cover.

- Discard the gasket.





63. Remove the crankshaft key.

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.





NOTE:Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
65. Remove the connecting rod cap bolts and cap.

- Discard the connecting rod cap bolts.





CAUTION:Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
66. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.

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

68. Remove the engine block from the stand and place on a workbench.





69. Remove the bolts and studs in the indicated sequence.

- Discard the lower cylinder block bolts.

- Remove the lower cylinder block.





70. Remove the crankshaft rear main seal.

- Remove the crankshaft.





71. Remove the crankshaft thrust bearing from the cylinder block.





NOTE:If the main bearings are being reused, mark them for correct position and orientation for reassembly.
72. Remove the bearings from the lower cylinder block.





NOTE:If the main bearings are being reused, mark them for correct position and orientation for reassembly.
73. Remove the crankshaft main bearings from the cylinder block.

74. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. See Cylinder Block Distortion Check, Piston Inspection and Connecting Rod Large End Bore.