Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Disassemble Procedure
- CAUTION:
Refer to Fastener Caution .
EN-42386-A Flywheel Holding Tool (1) - Install
- Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten the EN-42386-A Flywheel Holding Tool bolts to 50 N.m (37 lb ft)
- NOTE:
Do NOT DISCARD the crankshaft balancer bolt at this time.
Crankshaft Balancer Bolt (1) - Remove
- EN-41816-5 Crankshaft End Protector (3) - Install
- EN-41816-A Crankshaft Balancer Remover (4) - Install
- Crankshaft Balancer (2) - Remove
Mark or scribe the end of the crankshaft and the flex plate before removal.
- Automatic Transmission Flex Plate Bolt (1) - Remove [8x]
- Automatic Transmission Flex Plate (2) - Remove
Install the EN-51096 Crankshaft Rear Seal Remover (2) onto GE-23907-1 Slide Hammer (3).
- Slide the small bend of EN-51096 Crankshaft Rear Seal Remover between the lip of the rear seal (1) and crankshaft. Ensure that the small bend of EN-51096 Crankshaft Rear Seal Remover (2) engages the rear side of the rear seal (1). While rotating EN-51096 Crankshaft Rear Seal Remover (2) and GE-23907-1 Slide Hammer (3) around the seal, use the slide hammer to remove and DISCARD the seal.
Crankshaft Rear Oil Seal Housing Bolt (1) - Remove [12x]
- Crankshaft Rear Oil Seal Housing (2) - Remove
- Crankshaft Rear Oil Seal Housing Gasket (3) - Remove and DISCARD
- Crankshaft Rear Oil Seal Housing Locating Pin (4) - Remove
Oil Level Indicator (1) - Remove
- Oil Level Indicator Tube Bolt (2) - Remove
- Oil Level Indicator Tube (3) - Remove
- Oil Level Indicator Tube Seal (4) - Remove and DISCARD
- NOTE:
Spark plug wires will be removed with the valve rocker arm covers.
Exhaust Manifold Heat Shield Bolt (2) - Remove
- Exhaust Manifold Heat Shield - Left Side (3) - Remove [3x]
- Exhaust Manifold Bolt (4) - Remove [5x]
- Exhaust Manifold- Left Side (5) - Remove
- Exhaust Manifold Gasket (6) - Remove and DISCARD
- NOTE:
Spark plug wires will be removed with the valve rocker arm covers.
Exhaust Manifold Heat Shield Bolt (2) - Remove
- Exhaust Manifold Heat Shield - Right Side (3) - Remove [3x]
- Exhaust Manifold Bolt (4) - Remove [5x]
- Exhaust Manifold- Right Side (5) - Remove
- Exhaust Manifold Gasket (6) - Remove and DISCARD
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) - Loosen until disengaged [2x]
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (3) - Loosen until disengaged [2x]
- Fuel Feed Pipe Bolt (2) - Remove
- Fuel Feed Intermediate Pipe (3) - Remove and DISCARD
Fuel Pump Bolt (1) - Remove [2x]
- Fuel Pump Cover (2) - Remove
- Fuel Pump Bolt Retainer (3) - Remove [2x]
- Fuel Pump (4) - Remove
- Fuel Pump Bracket Gasket (5) - Remove and DISCARD
- NOTE:
Left side shown, right side similar.
Valve Rocker Arm Cover Bolt (1) - Remove [19x]
- Valve Rocker Arm Cover (2) - Remove [2x]
- Twist the spark plug wire boot a 1/2 turn and remove the spark plug wire from the gas engine ignition spark plug.NOTE:
- Spark plug wires will be removed with the valve rocker arm covers.
- Pull only on the spark plug wire boot to remove the wire.
- Inspect the spark plug wire for damage and replace if necessary.
- NOTE:
Left side shown, right side similar.
Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) - Remove and DISCARD [2x]
- NOTE:
Left side shown, right side similar.
Valve Rocker Arm (1) - Remove [16x]
- Valve Push Rod (2) - Remove [16x]
Remove the 2 engine ground wire bolts (1) and 2 ground wires (2) at the rear of the cylinder head.
- NOTE:
- Left side shown, right side similar.
- The cylinder head bolts are of a torque-to-yield design and are NOT to be reused.
Cylinder Head Bolt (1, 2, 3) - Remove and DISCARD [20x]
- Cylinder Head (4) - Remove [2x]
- Cylinder Head Gasket (5) - Remove and DISCARD [2x]
Engine Block Valley Cover Bolt (1) - Remove [9x]
Engine Block Valley Cover (1) - Remove
- Engine Block Valley Cover Gasket (2) @ Engine Block Valley Cover (1) - Remove and DISCARD
Valve Lifter Follower Guide Bolt (1) - Remove
- Valve Lifter Follower Guide (2) - Remove
- Valve Lifter Follower (3) - Remove
Valve Lifter Guide Bolt (1) - Remove [4x]
- Remove the valve lifter guide and valve lifters (2).
- Rotate the engine over on the engine stand.
Oil Pan Bolt (2) - Remove [2x]
- Oil Pan Bolt (1) - Remove [14x]
- Oil Pan (3) - Remove
- Rotate the engine over on the engine stand.
Install the EN-51096 Crankshaft Rear Seal Remover onto GE-23907-1 Slide Hammer.
- Slide the small bend of EN-51096 Crankshaft Rear Seal Remover between the lip of the front seal (1) and crankshaft. Ensure that the small bend of EN-51096 Crankshaft Rear Seal Remover engages the rear side of the front seal (1). While rotating EN-51096 Crankshaft Rear Seal Remover and GE-23907-1 Slide Hammer around the seal, use the slide hammer to remove and DISCARD the seal.
Camshaft Position Sensor Bracket Bolt (1) - Remove [2x]
- Camshaft Position Sensor Wire (2) - Remove
- Camshaft Position Sensor (3) - Remove
- Camshaft Position Actuator Magnet Bolt (4) - Remove [3x]
- Camshaft Position Actuator Magnet (5) - Remove
- Camshaft Position Actuator Magnet Gasket (6) - Remove and DISCARD
{If equipped} Disconnect the oil pump flow control solenoid wire (1).
- Engine Front Cover Bolt (2) - Remove [8x]
- Engine Front Cover Bolt (3) - Remove [2x]
- Engine Front Cover (4) Remove
Oil Pump Bolt (1) - Remove [4x]
- Oil Pump (2) - Remove
- NOTE:
- Do not use the camshaft position actuator solenoid valve again. Upon installation of the camshaft position actuator and timing chain, install a NEW valve.
- Do not apply threadlock to the flex plate bolts at this time.
Automatic Transmission Flex Plate (2) - Install
- Automatic Transmission Flex Plate Bolt (1) - Install and hand tighten [8x]
EN-42386-A Flywheel Holding Tool (1) - Install
- Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten the EN-42386-A Flywheel Holding Tool bolts to 50 N.m (37 lb ft)
Camshaft Position Actuator Solenoid Valve (1) - Remove and DISCARD
- WARNING:
Refer to Camshaft Position Actuator Removal and Installation Warning .
Loosen and separate the camshaft position actuator and timing chain from the camshaft. Position fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator.
Remove the camshaft position actuator solenoid valve (1) and timing chain (2).
- Insert a tie strap through the center of the actuator and over the reluctor wheel to hold it together.
Timing Chain Tensioner Bolt [2x](1) - Remove
- Timing Chain Tensioner (2) - Remove
Crankshaft Sprocket (1) - Remove
- Crankshaft Balancer Key (2) - Remove
Automatic Transmission Flex Plate Bolt (1) - Remove and DISCARD [8x]
- Automatic Transmission Flex Plate (2) Remove.
- EN - 42386-A Flywheel Holding Tool - Remove
Camshaft Retainer Bolt (1) - Remove [4x]
- Camshaft Retainer (2) - Remove
- Camshaft (3) - Remove
Use the EN-24270 Cylinder Bore Ridge Reamer (1) in order to remove the cylinder bore ring ridge, if required.
- Turn the crankshaft until the piston is at the bottom of the stroke.
- Place a cloth on top of the piston.
- Use the EN-24270 Cylinder Bore Ridge Reamer (1) to remove a cylinder ring ridge.
- Turn the crankshaft so the piston is at the top of the stroke.
- Remove the cloth.
- Remove the cutting debris from the cylinder and piston.
Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction.
- A stamping mark on the side of the connecting rod, at the crankshaft journal, may affect component geometry.
- Mark the top of the piston to the specific cylinder bore.
Mark, sort, or organize the connecting rod bearings so they may be installed to their original position and location. The connecting rods and the bearing caps are NOT interchangeable.
- Remove the connecting rod bolts (1), cap (2) and bearing (3).
Install the EN-41556 Connecting Rod Guide (2) to the connecting rod (1).
Using a hammer, tap lightly on the end of the EN-41556 Connecting Rod Guide (3) to remove the piston and connecting rod assembly (1) from the cylinder bore.
- Remove the EN-41556 Connecting Rod Guide (3).
Upon removal of the piston and connecting rod assembly (4), assemble the connecting rod cap (2) and bolts (1) onto the matching connecting rod.
Crankshaft Position Sensor Bolt (1) - Remove
- Crankshaft Position Sensor (2) - Remove
- NOTE:
The crankshaft bearing caps are machined with the engine block, for the proper clearances. Mark or identify each crankshaft bearing cap location and direction before removal. The crankshaft bearing caps MUST be installed to their original position and direction.
Crankshaft Bearing Cap Bolt- Inner (1) - Remove and DISCARD [10x]
- Crankshaft Bearing Cap Bolt- Outer (2) - Remove and DISCARD [10x]
- Crankshaft Bearing Cap Bolt - Side (3) - Remove and DISCARD [10x]
Before removal note the direction of the bearing caps arrows and location.
- CAUTION:
Refer to Fastener Caution .
Install the J-41818 Crankshaft Bearing Cap Remover (2) and tighten to 11 N.m (100 lb in).
- Install the J-6125-1B Slide Hammer (1) to the J-41818 Crankshaft Bearing Cap Remover (2).
- NOTE:
Use care when handling the crankshaft. Avoid damage to the CKP sensor reluctor ring teeth. Nicks, burrs or other damage to the teeth may affect on-board diagnostics (OBD) II system performance.
Crankshaft Bearing Cap (1) - Remove
[5x]
- Crankshaft Lower Bearing (2) - Remove [5x]
- Crankshaft (3) - Remove
- Crankshaft Upper Bearing (4) - Remove [5x]
- Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location.
- Lay the crankshaft onto 2 wooden V-blocks or other protective surface.
Knock Sensor Heat Shield Bolt (1) - Remove
- Knock Sensor Heat Shield (2) - Remove
- Knock Sensor Bolt (3) - Remove
- Knock Sensor (4) - Remove
Knock Sensor Bolt (1) - Remove
- Knock Sensor (2) - Remove
Transmission Locating Pin (1) - Remove [2x]
- Engine Block Oil Gallery Plug (2) - Remove
- Engine Block Coolant Drain Hole Plug (3) - Remove
- Engine Block Oil Gallery Plug (4) - Remove
Piston Oil Nozzle (1) - Remove [8x]
- Engine Block Oil Gallery Plug (2) - Remove
- Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores.
- Repair or replace the components, as required.
Select the expanding driver (4 - 8) and washer (2 or 3) from the EN-33049 Camshaft Bearing Service Set.
- Assemble the tool.
- Insert the tool through the front of the engine block and into the bearing.
- Tighten the expander assembly (11) nut until snug.
- Push the guide cone (1) into the front camshaft bearing in order to align the tool.
Drive the bearing (1) from the block bore.
- Repeat the above procedures in order to remove the remaining bearings.
Do NOT DISCARD the automatic transmission flex plate bolt at this time.
Use pry points to separate the crankshaft rear oil seal housing from the block.
After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
Use pry points to separate the engine front cover from the block.
A loose camshaft bearing may be caused by an enlarged, out of round, or damaged engine block bearing bore.
In order to remove the inner camshaft bearings, operate the tool from either end of the block, using the driver bar extension and the guide cone in the front or rear camshaft bearing bore.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.