Tools Required
J 24420-C Harmonic Balancer Puller. See Special Tools and Equipment .
Scheme 226
Scheme 227
- Remove the crankshaft balancer retaining bolt and washer.
- Remove the crankshaft balancer using the J 24420-C .
Scheme 228
- Remove the flywheel bolts.
- Remove the flywheel retainer.
- Remove the flywheel.
Scheme 229
- Remove the drive belt tensioner bolt.
- Remove the drive belt tensioner.
Scheme 230
- Remove the generator bracket bolts (1-4).
- Remove the generator bracket.
- Remove the front engine lift bracket.
Scheme 231
Scheme 232
- Remove the thermostat bypass pipe to throttle body nut (2).
- Remove the thermostat bypass pipe to throttle body hose clamps (1).
- Remove the thermostat bypass pipe to engine front cover bolt (4).
- Remove the thermostat bypass pipe hose clamp (5) and hose from pipe.
- Remove the thermostat bypass pipe (3).
- Remove the oil level indicator tube bolt.
- Remove the oil level indicator and oil level indicator tube.
Scheme 233
- Remove the oil filter bypass hole plug. IMPORTANT: Do not remove the oil filter fitting unless replacement or repair is needed.
- Remove the oil filter fitting, if necessary.
- Remove the oil filter bypass valve, by prying out with a suitable tool.
Scheme 234
Scheme 235
- Remove the spark plug wires.
- Remove the spark plugs.
- Remove the exhaust manifold heat shield bolts.
- Remove the exhaust manifold heat shield.
- Remove the exhaust manifold nuts.
- Remove the exhaust manifold.
- Remove the exhaust manifold gasket.
- Remove the exhaust studs, if required.
Scheme 236
Scheme 237
Scheme 238
- Remove the spark plug wires.
- Remove the spark plugs.
- Remove the EGR pipe from the exhaust manifold.
- Remove the heated oxygen sensor.
- Remove the exhaust manifold heat shield bolts.
- Remove the exhaust manifold heat shields.
- Remove the exhaust manifold nuts.
- Remove the exhaust manifold.
- Remove the exhaust manifold gasket.
- Remove the exhaust studs, if required.
Scheme 239
Scheme 240
- Remove the water outlet bolts.
- Remove the water outlet.
- Remove the thermostat.
Scheme 241
- Remove the valve rocker arm cover bolts. IMPORTANT: When removing the valve rocker arm cover make sure the gasket stays in place attached to the cylinder head.
- Remove the valve rocker arm cover and gasket.
- Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
- Remove the valve rocker arm cover.
- Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet, with suitable tool.
- Remove the valve rocker arm cover gasket.
Scheme 242
Scheme 243
- Remove the electronic ignition control module nuts and bolts.
- Remove the electronic ignition control module.
- Remove the electronic ignition control module studs.
- Remove the valve rocker arm cover bolts. IMPORTANT: When removing the valve rocker arm cover make sure the gasket stays in place attached to the cylinder head.
- Remove the valve rocker arm cover.
- Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
- Remove the valve rocker arm cover gasket.
Scheme 244
Scheme 245
Scheme 246
Scheme 247
Scheme 248
- Remove the MAP sensor electrical connector.
- Remove the MAP sensor bolts.
- Remove the MAP sensor from bracket.
- Remove the MAP sensor bracket and bracket bolt.
- Remove the EGR valve pipe and bolt from the EGR valve.
- Remove the EGR valve bolts.
- Remove the EGR valve and gasket.
- Remove the vacuum harness assembly.
- Remove the accelerator cable bracket and bracket bolts.
- Remove the purge valve bracket bolt, hose and valve assembly.
- Remove the throttle body bolts.
- Remove the throttle body and gasket.
- Remove the upper intake manifold bolts.
- Remove the upper intake manifold and gaskets.
Scheme 249
Scheme 250
Scheme 251
Scheme 252
- Remove the fuel feed and return pipe retaining clip bolt.
- Remove the fuel feed and return pipe retaining clip.
- Remove the fuel injector rail bolts.
- Remove the fuel injector rail assembly.
- Remove the heater inlet pipe nut.
- Remove the heater inlet pipe.
- Remove the lower intake manifold bolts.
- Remove the lower intake manifold.
Scheme 253
Scheme 254
Scheme 255
- Remove the valve rocker arm bolts. IMPORTANT: Place the valve train components in a rack in order to ensure that the components are installed in the same location from which they were removed.
- Remove the valve rocker arms.
- Remove the push rods. The intake push rods measure 146 mm (5.75 in). The exhaust push rods measure 152.51 mm (6.0 in).
- Remove the intake manifold gaskets.
Scheme 256
- Remove the valve lifter guide bolts.
- Remove the valve lifter guides. IMPORTANT: Once removed, place the valve lifters in an organized order so the valve lifters can be installed into the original locations.
- Remove the valve lifters.
Scheme 257
Scheme 258
- Remove the water pump pulley bolts.
- Remove the water pump pulley.
- Remove the water pump bolts.
- Remove the water pump.
- Remove the water pump gasket.
Scheme 259
Scheme 260
- Remove the cylinder head bolts.
- Remove the cylinder head.
- Remove the cylinder head gasket.
- Remove the dowel pins - cylinder head locator, if required.
Scheme 261
Scheme 262
- Remove the cylinder head bolts.
- Remove the cylinder head.
- Remove the cylinder head gasket.
- Remove the dowel pins - cylinder head locator, if required.
Scheme 263
- Remove the oil level pressure sensor and sensor bolt.
- Remove the oil pan side bolts.
- Remove the oil pan bolts.
- Remove the oil pan.
- Remove the oil pan gasket.
Scheme 264
Scheme 265
- Remove the oil pump bolt.
- Remove the oil pump and oil pump drive shaft.
- Remove the crankshaft oil deflector nuts.
- Remove the crankshaft oil deflector.
Scheme 266
- Remove the oil pump drive clamp bolt.
- Remove the oil pump drive clamp.
- Remove the oil pump drive.