Engine Disassemble

1. Draining Fluids and Oil Filter
a. Remove the oil pan drain plug. Allow the oil to drain.
b. Remove the oil filter.
c. Remove engine block coolant drain plugs. Allow the coolant to drain.





2. Remove Engine Flywheel
a. Remove the engine flywheel bolts
b. Remove the engine flywheel.
3. Remove Oil Level Indicator and Tube
a. Remove the oil level indicator from the oil indicator tube.
b. Remove the oil indicator tube bracket bolt from the right exhaust manifold.
c. Remove the oil level indicator tube.





4. Remove Exhaust Manifold
a. Remove the EGR valve inlet pipe from the intake manifold.
b. Remove the EGR valve inlet pipe from the left exhaust manifold.

CAUTION: Twist the spark plug boot one half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

c. Remove spark plug wire boots from spark plugs
d. Remove the exhaust manifold heat shield nuts.
e. Remove the spark plug heat shields.





f. Remove exhaust manifold nuts.
g. Remove the exhaust manifold and gasket.
h. Remove exhaust manifold studs.





5. Remove Water Pump
a. Remove the bypass hose and clamps.
b. Remove the bolts.
c. Remove the water pump.
d. Remove the gaskets.





6. Remove Crankshaft Balancer
^ Tools Required
- J 23523 F Crankshaft Balancer Puller and Installer, Or Equivalent

a. Remove the crankshaft balancer retaining bolt and washer.
b. Use the crankshaft balancer puller and installer in order to remove the crankshaft balancer.





7. Remove Distributor
a. Remove the spark plug wire clips from the spark plug wire brackets.
b. Remove the ignition coil wire from the ignition coil.
c. Remove the ignition coil bracket bolts from the upper intake manifold.
d. Remove the ignition coil from the upper intake manifold.





e. Remove the distributor hold down clamp bolt from the lower intake manifold.
f. Remove the distributor.





8. Remove Intake Manifold
a. Remove the upper intake manifold bolts.
b. Remove the upper intake manifold and the gaskets.
c. Remove the lower intake manifold bolts.





NOTE: Do not attempt to loosen the manifold by prying under the gasket surface with any tool. The lower intake manifold gaskets and seals are reusable.

d. Remove the lower intake manifold. Pull the lower intake manifold up.
e. Remove lower intake manifold gaskets and seals.





9. Remove Valve Rocker Arm Cover
a. Remove the valve rocker arm cover bolts.
b. Remove the valve rocker arm cover and gasket.
10. Remove Valve Rocker Arm and Push Rod
^ Tools Required
- J 3049 Valve Lifter Remover (Plier Type)
- J 9290 01 Valve Lifter Remover (Slide Hammer Type)
- Or Equivalents

NOTE: Every effort should be made to ensure that the mating parts are installed in their original locations during assembly.





a. A simple valve train component organizer rack can be made from a 50 mm by 200 mm (2 in by 8 inch) piece of wood. Use the following dimensions for the organizer
(1) 22 mm (7/8 inch)
(2) 55 mm (2 1/4 inch)
(3) 40 mm (1 1/2 inch)
(4) 10 mm (3/8 inch) drill bit, 25 mm (1 inch) deep
(5) 22 mm (7/8 inch) drill bit, 25 mm (1 inch) deep





b. Remove the following parts:
^ The valve rocker arm bolts
^ The valve rocker balls
^ The valve rocker arms
^ The valve pushrods guides.





c. Remove the valve pushrods
^ The exhaust valve pushrods are longer than the intake valve pushrods.





d. Remove the splash shield.





e. Remove the valve lifter guide retainer bolts and retainer.




f. Remove the valve lifter guides.
g. Remove the valve lifters.
^ Use a magnet in order to remove the valve lifters one at a time.
^ Place the valve lifters in the organizer rack, or tag them in a way to ensure they can be returned to the valve lifter bore from which they were removed.
^ Some valve lifters may be stuck in their bore due to gum or varnish deposits. These valve lifters can be removed using a valve lifter remover.





11. Remove Cylinder Head
a. Remove the cylinder head bolts.
b. Remove the cylinder head. Handle cylinder heads carefully to prevent damage to the gasket sealing surfaces.
c. Remove the cylinder gasket.





12. Remove Oil Pan
a. Remove the oil pan bolts.
b. Remove the oil pan.
c. Remove the oil pan gasket.





13. Remove Oil Pump
a. Remove the bolt that attaches the oil pump to the rear crankshaft bearing cap.
b. Remove the oil pump, the retainer, and the driveshaft from the rear crankshaft bearing cap.





14. Remove Engine Front Cover
a. Remove the engine front cover bolts.

NOTE: The engine front cover gasket is reusable.

b. Remove the engine front cover and the gasket.
15. Remove Timing Chain and Sprockets
^ Tools Required
- J 23509 A Crankshaft Sprocket Remover
- J 41371 Reluctor Wheel Remover
- Or Equivalents

NOTE: If the crankshaft sensor reluctor ring is removed, a new crankshaft sensor reluctor ring must be installed.





a. Remove the reluctor ring from the crankcase using reluctor wheel remover.
b. Measure the camshaft timing chain free play. If the chain can be moved back and forth in excess of 16 mm (0.625 inch), make a note that the camshaft timing chain and the sprockets must be replaced during assembly.





c. Remove the camshaft sprocket bolts.
d. Remove the camshaft sprocket and the camshaft timing chain.




e. Remove the crankshaft sprocket using crankshaft sprocket remover.
f. Remove the key, if necessary.





16. Remove Camshaft
a. Remove the camshaft retainer bolts and camshaft retainer.
b. Install three 5/16 18 x 4.0 inch bolts in the camshaft front bolt holes.
c. Carefully rotate and pull the camshaft out of the bearings.
17. Remove Piston, Connecting Rod, and Bearing
^ Tools Required
- J 24270 Ridge Reamer
- J 5239 Connecting Rod Guide Tool
- Or Equivalents





NOTE: Do not remove the excessive material from the cylinder bore. Excessive removal of material may require cylinder boring to the next oversize.

a. Remove the cylinder bore ridge as necessary.
1) Rotate the crankshaft until the piston is at Bottom Dead Center (BDC).
2) Place a cloth on top of the piston.
3) Perform the cutting operation with a ridge reamer. Refer to the manufacturers instructions before using the ridge reamer.
4) Remove the ridge reamer.
5) Rotate the crankshaft until the piston is at Top Dead Center (TDC).
6) Remove the cloth and the cuttings.
7) Repeat the procedure for each piston.

NOTE:
^ Place the matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods. Remove the connecting rod nuts.
^ If reusing, keep the bearings with their original connecting rod and connecting rod cap.

b. Wipe the oil from the bearings and the crankpins.
c. Remove the connecting rod cap and the bearing.





d. Remove the connecting rod and the piston out of the top of the engine block using the connecting rod guide tool.
e. Remove the remaining piston and the connecting rod assemblies.





18. Remove Crankshaft, Bearings, and Bearing Cap

NOTE: Check the crankshaft bearing caps for location markings. Mark the caps if necessary. The caps must be returned to the original Locations with the arrow pointing forward during assembly.

a. Remove the crankshaft bearing cap bolts.
b. Remove the crankshaft bearing caps.
c. Remove the crankshaft.
d. Remove the crankshaft upper bearings from the engine block.
e. Remove the crankshaft lower bearings from the crankshaft bearing caps.
f. Remove the rear crankshaft oil seal from the crankshaft.