Section 640 (Engine 6.8L): Disassembly: Engine

SPECIAL TOOL(S) 

Fig 1: Identifying Engine Special Tool(s)

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MATERIAL 

1. Remove the engine. For additional information, refer to Engine .
2. Remove the bolts and the flexplate.
   Fig 2: Removing Bolts And Flexplate

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3. Using the special tools, remove the crankshaft rear slinger.
   Fig 3: Removing Crankshaft Rear Slinger

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4. Using the special tools, remove the crankshaft rear seal.
   Fig 4: Removing Crankshaft Rear Seal

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5. Remove the bolts and the crankshaft rear seal retainer plate.
   Fig 5: Removing Bolts And Crankshaft Rear Seal Retainer Plate

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CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
   Fig 6: Removing Special Tool

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8. Install the special tool.
   Fig 7: Installing Special Tool (1 Of 2)

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9. Install the special tool.
   Fig 8: Installing Special Tool (2 Of 2)

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10. Mount the engine on a suitable work stand.
11. Remove the special tool.
    Fig 9: Removing Special Tool (1 Of 2)

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12. Remove the special tool.
    Fig 10: Removing Special Tool (2 Of 2)

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NOTE: RH shown, LH similar.
Fig 11: Removing RH And LH Engine Mounts
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13. Remove the RH and LH engine mounts.
NOTE: LH shown, RH similar.
Fig 12: Removing Cylinder Block Drain Plugs
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14. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
15. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 13: Disconnecting LH Radio Frequency Interference Capacitor

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16. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 14: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector

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17. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 15: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector

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18. Disconnect the knock sensor electrical connector, if equipped.
    Fig 16: Disconnecting Knock Sensor Electrical Connector

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19. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 17: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

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20. Disconnect the oil pressure switch electrical connector.
    Fig 18: Disconnecting Oil Pressure Switch Electrical Connector

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21. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown, LH similar.
Fig 19: Removing Nuts And Two Radio Interference Capacitors
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22. Remove the nuts and the two radio interference capacitors.
23. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 20: Removing Crankcase Ventilation Tube From LH Valve Cover

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24. Remove the nut attaching the oil level indicator tube to the front of the engine.
    Fig 21: Removing Nut Attaching Oil Level Indicator Tube To Front Of Engine

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25. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
    Fig 22: Removing Bolt Attaching Oil Level Indicator Tube To Rear Of Engine

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26. Position the oil level indicator tube aside.
    Fig 23: Positioning Oil Level Indicator Tube Aside

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CAUTION: 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: The bolts are part of the valve cover and should not be removed.
Fig 24: Removing LH Valve Cover
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27. Remove the LH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
CAUTION: 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: The bolts are part of the valve cover and should not be removed.
Fig 25: Removing RH Valve Cover
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28. Remove the RH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
29. Remove the bolt and the idler pulley.
    Fig 26: Removing Bolt And Idler Pulley

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30. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
    Fig 27: Removing Water Pump Pulley

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31. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
    Fig 28: Removing And Discard Crankshaft Pulley Bolt

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32. Use the special tool to remove the crankshaft front oil seal.
    Fig 29: Removing Crankshaft Front Oil Seal

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33. Remove the power steering pump.
    Fig 30: Removing Power Steering Pump

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34. Remove the bolts.
    Fig 31: Removing Bolts

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NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Fig 32: Removing Fasteners
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35. Remove the fasteners.
36. Remove the engine front cover from the cylinder block.
    Fig 33: Removing Engine Front Cover From Cylinder Block

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37. Remove the crankshaft sensor ring from the crankshaft.
    Fig 34: Removing Crankshaft Sensor Ring From Crankshaft

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CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur.
Fig 35: Removing Balance Shaft Bearing Caps
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38. Remove the six bolts and remove the balance shaft bearing caps.
39. Remove the balance shaft.
    Fig 36: Removing Balance Shaft

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CAUTION: Use care when removing the spark plugs.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
40. Remove the 10 spark plugs.
41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 37: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage

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NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
Fig 38: Using Special Tool To Compress Valve Springs
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42. Use the special tool to compress the valve springs and remove the camshaft roller followers.
43. Remove the special tool.
    Fig 39: Removing Special Tool

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44. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 40: Positioning Crankshaft With Keyway At 12 O'Clock Position

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45. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
    Fig 41: Removing Timing Chain Tensioning System From Both Timing Chains

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46. Remove the RH and LH timing chains and the crankshaft sprocket(s).
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain from the crankshaft sprocket.
    Fig 42: Removing RH And LH Timing Chains And Crankshaft Sprocket(s)

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47. Remove both timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
    Fig 43: Removing Timing Chain Guides

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48. Remove the RH exhaust manifold.
    • Remove the nuts.
    • Remove the RH exhaust manifold.
    • Remove the RH exhaust manifold gasket.
    Fig 44: Removing RH Exhaust Manifold & Gasket

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49. Remove the LH exhaust manifold.
    • Remove the nuts.
    • Remove the LH exhaust manifold.
    • Remove the LH exhaust manifold gasket.
    Fig 45: Removing LH Exhaust Manifold & Gasket

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50. Clean and inspect the exhaust manifolds. For additional information, Refer to BRAKE SYSTEM-GENERAL INFORMATION .
51. Install the special tools on both ends of the cylinder head.
    Fig 46: Installing Special Tools On Both Ends Of Cylinder Head

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NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
52. Remove the hydraulic lash adjusters.
CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield and cannot be reused.
CAUTION: 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 which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: RH shown, LH similar.
Fig 47: Removing RH Cylinder Head
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53. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
CAUTION: 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 which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or 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 surfaces.
54. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    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 remaining 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 surface is normal.
NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
55. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
56. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
    Fig 48: Removing Bolts And Nut Retaining Oil Filter Adapter To Cylinder Block

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57. Remove the bolts.
    Fig 49: Removing Water Pump Bolts

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58. Remove the water pump from the cylinder block.
    Fig 50: Removing Water Pump From Cylinder Block

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59. Remove the bolts and the A/C compressor.
    Fig 51: Removing Bolts And A/C Compressor

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60. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
    Fig 52: Removing Ridge Or Carbon Deposits From Each Cylinder Using A Cylinder Ridge Reamer

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61. Remove the bolts, the oil pan and the oil pan gasket.
    Fig 53: Removing Oil Pan And Oil Pan Gasket

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62. Remove the bolts, the oil pump screen cover and tube and the spacer.
    Fig 54: Removing Bolts Oil Pump Screen Cover And Tube And Spacer

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63. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
    Fig 55: Removing Oil Pump

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CAUTION: Make sure connecting rods and rod caps are numbered to keep them in the correct orientation.
Fig 56: Removing Connecting Rod Caps
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64. Remove the bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is a bottom dead center.
    • Remove and discard the bolts.
CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
Fig 57: Removing Piston And Rod Assembly
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65. Remove the piston and rod assembly.
    • Using the special tool, guide the piston and rod assembly out of the cylinder.
66. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
67. Remove and discard the 12 cross-mounted bolts.
    Fig 58: Removing And Discard Cross-Mounted Bolts

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68. Remove and discard the bolts.
    Fig 59: Removing And Discard Bolts

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69. Remove the main bearing cap dowel pins.
    Fig 60: Removing Main Bearing Cap Dowel Pins

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70. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 61: Removing Main Bearing Caps Lower Crankshaft Main Bearings And Thrust Washer

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71. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 62: Removing Crankshaft And Crankshaft Main Bearings From Cylinder Block

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