Disassembly Procedure
TOOL REQUIREDJ 36660 Torque Angle Meter
J 24420-B Crankshaft Balancer Remover
J 29113 Crankshaft Balancer Installer
J 5825-A Crankshaft Sprocket Remover
J 24270 Ridge Reamer
J 33049 Camshaft Bearing Remover/Installer
DISASSEMBLY STEPS
1. Draining Fluids and Oil Filter Removal
a. Remove the oil drain plug.
b. Drain the engine oil.
c. Remove the oil filter.
d. Remove the drain plugs.
e. Drain the coolant.
2. Engine Flex Plate Removal
a. Remove the flex plate bolts. Use the Flex Plate Holding Tool.
b. Remove the flex plate retainer.
c. Remove the flex plate.
3. Oil Level Indicator and Tube Removal
a. Remove the oil level indicator bolt.
b. Remove the oil level indicator.
c. Remove the oil level indicator tube assembly with a pair of pliers.
4. Upper Intake Manifold Removal
a. Remove the fuel injector sight shield. Refer to Engine Cover Replacement
b. Remove the evaporator emission canister purge solenoid bracket bolts.
c. Remove the evaporator emission canister purge solenoid and brackets.
d. Remove the spark plugs wires from the coils.
e. Remove the control module mounting bolts.
f. Remove the control module and the coils.
g. Remove the control module mounting bracket bolts.
h. Remove the control module mounting bracket.
i. Remove the vacuum hose at the manifold.
j. Remove the upper intake manifold mounting bolts.
k. Remove the upper intake manifold and gasket.
5. Lower Intake Manifold Removal
a. Remove the fuel feed and return pipe retaining clip bolt.
b. Remove the fuel feed and return pipe retaining clip.
c. Remove the engine coolant sensor electrical connector.
d. Remove the camshaft position sensor electrical connector.
e. Remove the fuel injector rail mounting bolts.
f. Remove the fuel injector rail.
g. Remove the coolant by-pass pipe hose clamp from the water inlet.
h. Remove the water inlet mounting bolt and stud.
i. Remove the water inlet and gasket.
j. Remove the coolant by-pass pipe mounting bolt at the oil level indicator.
k. Remove the coolant by-pass pipe.
l. Remove the water outlet mounting bolts.
m. Remove the water outlet and thermostat.
n. Remove the lower intake manifold mounting bolts.
o. Remove the lower intake manifold and gasket.
6. Oil Distribution Cover Removal
a. Remove the oil distribution cover mounting bolts.
b. Remove the oil distribution cover.
c. Remove the oil distribution cover gasket.
d. Clean any gasket material from the oil distribution cover mating surfaces.
7. Exhaust Manifold Removal (Left Side)
a. Disconnect the Air pipe.
b. Remove the exhaust manifold retaining nuts.
c. Remove the exhaust manifold and the heat shield.
d. Remove the exhaust manifold gasket.
8. Exhaust Manifold Removal (Right Side)
a. Remove the heated oxygen sensor.
b. Remove the exhaust manifold retaining nuts.
c. Remove the exhaust manifold and the heat shield.
d. Remove the exhaust manifold gasket.
9. Timing Belt Cover Removal (Left Side)
a. Remove the left timing belt cover retaining bolts.
b. Remove the left timing belt cover.
10. Timing Belt Cover Removal (Right Side)
a. Remove the right timing belt cover retaining bolts.
b. Remove the right timing belt cover.
11. Timing Belt Cover Removal (Center)
a. Remove the drive belt tensioner.
b. Remove the center retaining bolts.
c. Remove the center timing belt cover.
12. Timing Belt Removal
^ Remove the camshaft timing belt.
13. Camshaft Carrier Cover Removal (Left Side)
a. Remove the camshaft position sensor mounting bolt.
b. Remove the camshaft position sensor.
c. Remove the spark plug wires.
d. Remove the camshaft carrier cover bolts.
e. Remove the camshaft carrier cover.
f. Remove the gasket from the camshaft carrier cover.
g. Remove the wrings from the camshaft carrier cover.
14. Camshaft Carrier Cover Removal (Right Side)
a. Remove the spark plug wires.
b. Remove the camshaft carrier cover bolts.
c. Remove the camshaft carrier cover.
d. Remove the gasket from the camshaft carrier cover.
e. Remove the wrings from the camshaft carrier cover.
15. Timing Belt Tensioner Actuator Removal
a. Remove the bolts and the side plate from the camshaft timing belt tensioner actuator.
b. Rotate the camshaft timing belt tensioner actuator from the tensioner pulley socket and out of the mounting base. Removal of the actuator from the tensioner pulley allows it to extend to its maximum travel.
16. Timing Belt Tensioner Pulley Removal
a. Remove the camshaft tensioner pulley bolt.
b. Remove the camshaft tensioner pulley and the arm assembly.
c. Remove the tensioner mounting bracket retaining bolts.
d. Remove the tensioner mounting bracket and gasket.
17. Timing Belt Idler Pulley Removal
a. Remove idler pulley bolts.
b. Remove the idler pulleys.
18. Camshaft Intermediate Drive Sprocket Removal
a. Remove the intermediate shaft belt sprocket retaining bolt.
CAUTION: Hitting the nose of the intermediate shaft and/or prying the sprocket will cause thrust bearing damage.
b. Remove the intermediate drive shaft sprocket using Crankshaft Pulley Hub Puller tool and three self tapping bolts.
c. Use seat belt anchor bolts or an equivalent.
19. Camshaft Driven Sprocket Removal
a. Remove the camshaft sprocket bolt and the taper wedge using Camshaft Timing Clamps tool in order to hold the camshaft.
b. Remove the camshaft sprocket by lightly tapping the sprocket using a soft faced hammer.
20. Crankshaft Pulley Removal
a. Hold the flex plate using Holder tool.
b. Remove the crankshaft balancer bolt.
c. Remove the crankshaft pulley bolts.
d. Remove the crankshaft pulley.
21. Crankshaft Balancer Removal
^ Remove the crankshaft balancer using Crankshaft Balancer Remover tool.
22. Oil Pan Removal
a. Remove the oil pan retaining nuts, bolts, and reinforcements.
b. Remove the oil pan.
c. Remove the oil pan gasket.
23. Oil Pump Removal
a. Remove the mounting bolt.
b. Remove the oil pump and drive rod.
24. Crankshaft Oil Deflector Removal
a. Remove the crankshaft oil deflector mounting nuts.
CAUTION: Do not attempt to remove the pick up tube.
b. Remove the crankshaft oil deflector.
25. Oil Pump Drive Removal
a. Remove the oil pump drive mounting bolt and clamp.
b. Remove the oil pump drive.
c. Remove the oil pump drive o-ring.
26. [1][2]Engine Front Cover Removal
a. Remove the engine front cover bolts.
b. Remove the [1][2]engine front cover.
c. Remove the [1][2]engine front cover gasket.
27. Cam Inter Drive Shaft Chain, Sprockets Removal
a. Remove the timing chain tensioner bolts.
b. Remove the timing chain, the crankshaft sprocket, and the intermediate shaft sprocket as an assembly. Use Universal Sprocket Puller tool and Crankshaft Sprocket Puller tool in order to remove the crankshaft sprocket.
c. If the intermediate drive shaft sprocket does not slide off easily with the timing chain assembly, rotate the crankshaft back and forth in order to help loosen the tight fit.
d. Remove the timing tensioner.
28. Camshaft Carrier Removal (Left Side)
a. Remove the rear torque strut mounting bolts.
b. Remove the rear torque strut.
c. Remove the camshaft carrier retaining bolts.
CAUTION: Install the six fuel line hoses under the camshaft and between the lifters in order to hold. the lifters in the camshaft carrier. The exhaust uses a 6 x 3/16 inch fuel line hose. The intake uses a 6 x 5/32 inch fuel line hose.
d. Remove the camshaft carrier.
e. Remove the camshaft carrier gasket.
29. Camshaft Carrier Removal (Right Side)
a. Remove the camshaft carrier retaining bolts.
b. Install six fuel line hoses under the camshaft, and between the lifters in order to hold the lifters in the camshaft carrier.
^ Exhaust uses 6 x 3/16 inch fuel line hose.
^ Intake uses 6 x 5/32 inch fuel line hose.
c. Remove the camshaft carrier.
d. Remove the camshaft carrier gasket.
30. Valve Lifter Removal
CAUTION: Keep the lifters in order. Do this in order to ensure proper installation.
a. Disconnect the lifter hold down hoses.
b. Remove the lifters.
31. Camshaft Removal
CAUTION: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
a. Remove the thrust plate cover mounting bolts.
b. Remove the thrust plate cover and the gasket.
c. Remove the thrust plate mounting bolts and the thrust plate.
d. Stand the camshaft carrier vertically on the end.
e. Remove the camshaft by carefully removing the camshaft out of the back of the camshaft carrier.
32. Cylinder Head Removal (Left Side)
a. Remove the cylinder head bolts.
b. Remove the cylinder head.
c. Remove the cylinder head gasket.
33. Cylinder Head Removal (Right Side)
a. Remove the cylinder head bolts.
b. Remove the cylinder head.
c. Remove the cylinder head gasket.
34. Connecting Rod and Piston Removal
a. Mark the piston with the number of the cylinder from which the cylinder is being removed.
b. Mark the connecting rod and the rod cap so that the rod and cap can be assembled correctly.
c. Turn the crankshaft to the bottom dead center.
d. Clean the carbon from the top end of the cylinder.
e. Remove the connecting rod nut and cap.
CAUTION: If there is a pronounced ridge at the top of the piston travel, the ridge must be removed with a ridge reamer before the piston and connecting rod assembly are removed. Applying force may break the piston rings or damage the piston. Install thread protector in order to avoid damage to the crankshaft journal.
f. Remove the connecting rod and piston assembly. Push the assembly out with a suitable tool.
35. Crankshaft Rear Oil Seal Removal
^ Remove the rear main oil seal from the crankshaft.
36. Crankshaft Removal
a. Remove the main bearing cap bolts.
b. Remove the main bearing caps and lower bearing halves.
c. Remove the crankshaft.
d. Remove the upper bearing halves.
37. Cam Inter Drive Shaft Removal
a. Remove the retainer screws.
b. Remove the retainer.
CAUTION: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
c. Remove the intermediate shaft.
38. Camshaft Intermediate Drive Shaft Bearing Removal
CAUTION: The intermediate shaft bearings must not be reused after removal.
a. Remove the intermediate shaft cup plug.
b. Remove the intermediate shaft bearings.
c. Select the proper expander assembly and the proper driving washer.
d. Assemble Camshaft Bearing Remover/Installer tool.
e. Tighten the expander assembly snug with the intermediate shaft bearing.
f. Drive the intermediate shaft bearings out of the shaft assembly.
39. Cylinder Block Disassemble
a. Remove the knock sensor.
b. Remove the crankshaft position sensor retaining bolt and sensor.
c. Remove the coolant jacket plugs.
d. Remove the coolant jacket threaded plugs.
CAUTION: Caustic cleaning solution destroys the bearing material. All bearings must be replaced after cleaning with a caustic solution. Do not clean bearing material or aluminum parts with caustic solutions.
e. Remove the oil gallery plugs.