Disassembly

1. Loosen the bolts.
2. Remove the drive belt.





3. Remove the bolts and the water pump pulley.





4. Remove the bolts and the water pump.





5. If necessary, remove the bolt and remove the drive belt tensioner.





6. Remove the bolts and the generator mounting bracket.





7. Remove the nuts and remove the water bypass tube and hose at the thermostat.





8. Disconnect the engine control sensor wiring from the A/C compressor.





9. Remove the bolts from the A/C compressor and remove the A/C compressor.





10. Remove the EGR Vacuum Regulator (EVR) solenoid and bracket assembly.
1 Disconnect connector from EGR vacuum regulator.
2 Remove the retaining nuts from the EGR vacuum regulator control and bracket assembly.
3 Remove two vacuum lines and remove the EGR vacuum regulator control and bracket assembly.





11. Remove the bolts from both ignition coil covers and remove the ignition coil cover.





12. Remove the RH and LH ignition coil wiring assembly from the ignition coils.
1 Disconnect the ignition coil electrical connectors from the ignition coils.
2 Pull and remove the ignition coils.





13. Remove the generator wiring.





14. Loosen bolts and remove the generator.
15. Remove the EGR valve and tube.
16. Remove the differential pressure feedback EGR and bracket assembly.





17. Disconnect the vacuum hose and electrical connector from the fuel pressure regulator.





18. Remove the crankcase vent connector and hose.





19. Disconnect the electrical connector from the Idle Air Control (IAC) valve.





20. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor.





21. Disconnect the connector from the Throttle Position (TP) sensor.





22. Disconnect the connectors from the Knock Sensors (KS).





23. Disconnect the low oil level sensor.





24. Disconnect the camshaft position sensor electrical connector.





25. Disconnect the fuel charging wiring.





26. Remove the bolts from the upper intake manifold and the intake airflow spacers in the sequence shown. Remove the intake manifold and the airflow spacers as an assembly.





27. Remove the bolt from the belt idler pulley and remove the belt idler pulley.





28. NOTE: Right manifold shown left similar.

Remove the nuts from the RH and the LH exhaust manifold and remove the exhaust manifolds.





29. Remove the nuts and remove the oil level indicator tube.





30. Remove the oil bypass filter.





31. Remove the bolts and remove the oil filter adapter.





32. Remove the water outlet tube.
^ Remove the bolts.
^ Remove the water outlet tube.





33. Remove the bolts and the studs and remove the RH valve cover.





34. Remove the bolts and the studs and remove the LH valve cover.





35. Remove the bolts and remove the engine front cover.





36. Remove the crankshaft position sensor pulse wheel.





37. Release the ratchet lock while the piston is being compressed.





38. Remove the RH and LH timing chain tensioner.
1 Compress the timing chain tensioner and install the retaining pins.
2 Remove the bolts and remove the timing chain tensioner.





39. Remove the RH and LH timing chain tensioner arms, the camshaft sprocket and the timing chains.





40. Remove the bolts from the RH and LH timing chain guides and remove the timing chain guides.





41. Remove the bolts from the RH and LH cylinder head and remove the cylinder heads.





42. Remove the bolts and the knock sensors.





43. Remove the bolts and remove the oil pan.





44. Remove the bolts and remove the oil pump screen cover and tube and spacer.





45. Remove the bolts and remove the oil pump.





46. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger.





47. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal.





48. Remove the bolts and remove the crankshaft rear oil seal retainer.





49. Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using Cylinder Ridge Reamer following manufacturer's instructions.





50. CAUTION: Do not stamp the top of pistons, as ring land damage may occur.

NOTE: Connecting rods and rod caps should be numbered to keep the proper orientation in the following sequence.

Remove the bolts and the connecting rod caps for piston number 1 and 6.
51. Discard the bolts.





52. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Use the Cylinder Rod Guide Tool to push the pistons number 1 and 6 through the top of the cylinder block.
53. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90° and repeat Steps 60-62.





54. Remove the side bolts.





55. Remove and discard the bolts.





56. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.





57. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft main bearings from the cylinder block.