Disassemble Procedure
Engine Front Cover (1) - Remove - Engine Front Cover Removal and Installation
- Timing Chain - Remove - Camshaft Timing Chain Component Removal and Installation
Vacuum Pump Bolt (1) - Remove [2x]
- Vacuum Pump (2) - Remove
Fuel Injection Fuel Rail Noise Shield (1) - Remove
Cylinder Head Bolt (1) - Remove and DISCARD [2x]
- Cylinder Head Bolt (2) - Remove and DISCARD [8x]
- Cylinder Head (3) - Remove
Cylinder Head Gasket (1) - Remove and DISCARD
Cylinder Head Bolt (1) - Remove and DISCARD
- Cylinder Head Bolt (2) - Remove and DISCARD [8x]
- Cylinder Head (3) - Remove
Cylinder Head Gasket (1) - Remove and DISCARD
Fuel Injection Fuel Rail Noise Shield (1) - Remove
Oil Pan Bolt (1, 2, 3) - Remove
- Oil Pan (4) - Remove
- NOTE:
Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Remove any RTV sealant (1) from the cover mating surface (2) using the EN-28410 Gasket Remover (3).
- Clean out debris from the bolt holes (4).
- An arrow/dot showing proper piston orientation is located on the top of the piston.
- If the connecting rod bearings have been used in a running engine, you must replace them with NEW connecting rod bearings for reassembly.
- Before removing the connecting rods, check the connecting rod side clearance using the following procedure:
- Tap the connecting rod to one end of the crankshaft journal with a dead-blow or wooden hammer.
- Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.
- The connecting rod side clearance should not exceed specifications. Engine Mechanical Specifications
- If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod. Piston and Connecting Rod Overhaul
- If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.
- If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
- Using a marker, number each piston face. Draw an arrow along the centerline of the piston pointing toward the front of the engine.
- Mark the cylinder number on the connecting rod and the connecting rod cap with a scribe, paint stick or permanent marker.
- CAUTION:
Powdered metal connecting rods have rod bolts which yield when torqued. If the rod bolts are loosened or removed the rod bolts must be replaced. Rod bolts that are not replaced will not torque to the correct clamp load and can lead to serious engine damage.
Remove the connecting rod bolts (1).
- Remove the connecting rod cap (2).
Install the EN-46121 Connecting Rod Guide Pin Set (1) into the connecting rod bolt holes.
Using the EN-46121 Connecting Rod Guide Pin Set, push the connecting rod and piston assembly (1) through the top of the cylinder. DO NOT scratch the crankshaft journal or cylinder wall and DO NOT damage the oil jets when removing the connecting rod and piston assembly.
Remove the EN-46121 Connecting Rod Guide Pin Set (3) from the connecting rod bolt holes.
- Remove and DISCARD the upper connecting rod bearing (1) from the connecting rod (2).
Remove and DISCARD the lower connecting rod bearing (1) from the connecting rod cap (2).
Reattach the connecting rod cap (1) to the connecting rod (2) to prevent damage to their mating surfaces. The cap (1) and connecting rod (2) are a matched set and must be kept together.
Do not use a stamp, punch or any other method that may distort or stress the connecting rod or connecting rod cap. Extensive engine damage may result from a connecting rod that is distorted or stressed.
The connecting rod caps must remain with the original connecting rod.