Disassembly

1. Remove the engine from the vehicle.
2. Use Oil Filter Wrench D79L-6731-B or equivalent to remove the oil filter.





3. Remove the adjustment bolt and the generator bolt. Refer to Starting and Charging.
4. Remove the Generator (GEN).
5. Use Strap Wrench D85L-6000-A or equivalent and remove the three water pump pulley bolts.
6. Remove the water pump pulley.





7. Remove the four crankshaft pulley retaining washer bolts and the crankshaft pulley retaining washer. Remove the crankshaft pulley bolt.
8. Remove the strap wrench and remove the outer crankshaft pulley (if equipped) and the inner crankshaft pulley.





9. Remove the four upper engine front cover bolts and the upper engine front cover.
10. Remove the two lower engine front cover bolts and the lower engine front cover.





11. Remove the timing belt tensioner spring, spring cover, and the timing belt tensioner bolt.
12. Mark the direction of the rotation on the timing belt.
13. Remove the timing belt.





14. Remove the four water pump bolts and remove the water pump and water inlet connection.
15. Remove the water pump housing gasket.
16. Remove the six valve cover bolts.
17. Remove the valve cover and valve cover gasket.





18. Remove the crankshaft pulley bolt.
19. Remove the crankshaft pulley hub, crankshaft sprocket and crankshaft key.
20. Remove the intake manifold support bolts and the intake manifold support.
21. Remove the eight intake manifold bolts and nuts.
22. Remove the intake manifold and intake manifold gasket.
23. Remove the exhaust manifold shield bolts. Remove the exhaust manifold shield.
24. Remove the four exhaust manifold bolts and three exhaust manifold nuts.
25. Remove the exhaust manifold and exhaust manifold gasket.
26. Remove the cylinder head bolts.
27. Remove the cylinder head and head gasket.
28. Remove the oil pressure sensor.





29. Remove the three engine support insulator mounting bracket bolts and the engine support insulator mounting bracket.
30. Remove the oil pan bolts and nuts.
31. Remove the oil pan and oil pan gasket.
32. Remove the Crankshaft Position (CKP) sensor and remove the six oil pump bolts.





33. Remove the oil pump, oil pump screen cover and tube, oil level indicator tube assembly, and gasket.

NOTE: Repeat the following five steps for each of the connecting rod and piston assemblies. Mark each connecting rod and piston assembly with its applicable cylinder number to aid in installation.





34. Remove the connecting rod nuts.
35. Remove the connecting rod caps and the lower connecting rod bearings.
36. To prevent scratching of the crankshaft journal surface, install a piece of rubber hose on the connecting rod studs.





37. If necessary, install Cylinder Ridge Reamer T64L-6011-EA in the cylinder bore. Remove the ridge at the top of the cylinder bore.





38. Use a hammer handle or a piece of wood to tap the connecting rod and piston assembly upward until the piston rings clear the top of the cylinder block.





39. Remove the 10 crankshaft main bearing cap bolts.
40. Remove the crankshaft main bearing caps and the lower crankshaft main bearings.

CAUTION: Use care not to damage the bearing journals while removing the crankshaft.

41. Remove the crankshaft from the cylinder block.
42. Remove the upper crankshaft main bearings from the cylinder block.