Part 2

DISASSEMBLY (Steps 39-66)

Engine

39. Remove the engine plug bolt.





40. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly.

Install the Crankshaft TDC Timing Peg.





41. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced, remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
^ Remove and discard the crankshaft pulley bolt and washer.
^ Remove the crankshaft pulley.
^ Remove the diamond washer and discard.





42. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the Oil Seal Remover, remove the crankshaft front seal.





43. Remove the 2 bolts and the CKP sensor.





44. Remove the 22 bolts and the engine front cover.





45. Compress the timing chain tensioner in the following sequence.
1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.





46. Remove the 2 bolts and the timing chain tensioner.





47. Remove the RH timing chain guide.





48. Remove the timing chain.





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





50. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.





51. Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.





52. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.

Remove the oil pump chain and sprockets.
1. Remove the bolt.
2. Remove the chain and sprockets.





53. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.





54. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.





NOTE: Mark the location and orientation of each camshaft bearing cap.

Remove the camshafts from the engine.
^ Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
^ Remove the camshaft bearing caps.
^ Remove the camshafts.

55. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

Remove the valve tappets.

56. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.

Inspect the valve tappets.

57. Remove the cylinder head.
^ Remove and discard the 10 cylinder head bolts.
^ Remove the cylinder head.
^ Remove and discard the cylinder head gasket.





58. Remove the cylinder head alignment dowels.





59. NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

60. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.

61. Remove the 13 bolts and the oil pan.





62. Remove the 6 bolts and the crankshaft rear seal with retainer plate.





63. Remove the 2 bolts, oil pump pickup tube and gasket.
^ Discard the gasket.





64. Remove the 4 bolts and the oil pump.





65. Remove the Crankshaft TDC Timing Peg.





66. 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.