Section 19 (Engine - 6.8L): Disassembly: Engine

Special Tool(s) 

Fig 1: Identifying Special Tools (1 Of 3)

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Fig 2: Identifying Special Tools (2 Of 3)

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Fig 3: Identifying Special Tools (3 Of 3)

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1. Remove the flexplate.
   Fig 4: Removing Flexplate

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2. Using the special tools, remove the crankshaft oil slinger.
   Fig 5: Removing Crankshaft Oil Slinger Using Special Tools

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3. Using the special tools, remove the crankshaft rear oil seal.
   Fig 6: Removing Crankshaft Rear Oil Seal Using Special Tools

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4. Remove the bolts and the rear crankshaft seal retainer plate.
   Fig 7: Removing Bolts And Rear Crankshaft Seal Retainer Plate

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5. Place the engine on a suitable engine stand.
6. Remove the Modular Engine Lift Bracket.
7. Remove the engine wiring harness.
8. Remove the bolts, the oil pan, and the oil pan gasket.
   Fig 8: Removing Bolts, Oil Pan And Oil Pan Gasket

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9. Remove the two bolts, the nut, the oil pump screen cover and tube, and the spacer.
   Fig 9: Removing Bolts, Nut, Oil Pump Screen Cover And Tube And Spacer

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NOTE: LH shown; RH similar.
NOTE: The bolts are a part of the valve cover and are not to be removed.
Fig 10: Removing Valve Cover
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10. Fully loosen the sixteen bolts, and remove the valve cover and the valve cover gasket.
11. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
    Fig 11: Removing Water Pump Pulley

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12. Remove the bolts.
    Fig 12: Removing Bolts

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13. Remove the water pump from the cylinder block.
    Fig 13: Removing Water Pump From Cylinder Block

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14. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 14: Removing Crankshaft Pulley Bolt Using Special Tool

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15. Using the special tool, remove the crankshaft front seal.
    Fig 15: Removing Crankshaft Front Seal Using Special Tool

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16. Remove the bolt and the belt idler pulley.
    Fig 16: Removing Bolt And Belt Idler Pulley

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17. Remove the engine front cover fasteners.
    Fig 17: Removing Engine Front Cover Fasteners

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18. Remove the engine front cover from the front cover to cylinder block dowels.
    Fig 18: Removing Engine Front Cover From Front Cover To Cylinder Block Dowels

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19. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
20. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 19: Installing Special Tool Between Valve Spring Coils

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NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
Fig 20: Compressing Valve Springs Using Special Tool
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21. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
22. Remove the special tool.
    Fig 21: Removing Special Tool

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23. Remove the crankshaft sensor ring from the crankshaft.
    Fig 22: Removing Crankshaft Sensor Ring From Crankshaft

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CAUTION: The bearing caps must be marked for installation in their original location or engine damage can occur.
Fig 23: Removing Bolts And Bearing Caps
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Fig 24: Removing Bolts And Balance Shaft
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24. Remove the six bolts, the bearing caps and the balance shaft.
CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Fig 25: Positioning Crankshaft With Keyway At 12 O'Clock Position
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25. Position the crankshaft with the keyway at the 12 o'clock position.
26. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins.
    Fig 26: Removing Bolts And Timing Chain Tensioners

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CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Fig 27: Removing LH And RH Timing Chain And Crankshaft Sprocket
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27. Remove the LH and RH timing chain and the crankshaft sprocket.
    • 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 and the crankshaft sprocket.
28. Remove the timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
    Fig 28: Removing Timing Chain Bolts And Guides

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29. Remove the 10 nuts and the RH exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket.
    Fig 29: Removing Nuts And RH Exhaust Manifold And Exhaust Manifold Gasket

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30. Remove the 10 nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.
    Fig 30: Removing Nuts And LH Exhaust Manifold And Exhaust Manifold Gasket

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31. Remove the oil level indicator, the bolt and the oil level indicator tube.
    Fig 31: Removing Oil Level Indicator, Bolt And Oil Level Indicator Tube

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32. Install the special tools on both ends of the cylinder head.
    Fig 32: Installing Special Tools On Both Ends Of Cylinder Head

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CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.
NOTE: LH shown; RH similar.
Fig 33: Removing Bolts And Cylinder Head
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33. Remove the bolts and the cylinder head.
    • Discard the head gasket and clean the engine block surface.
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 scraper to remove all traces of the head gasket.
34. Discard the cylinder head gaskets. Clean the engine block sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
35. Remove the bolts and the engine mounts.
36. 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 34: Removing Bolts And Nut Retaining Oil Filter Adapter To Cylinder Block

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37. Remove the bolts and the oil pump.
    Fig 35: Removing Bolts And Oil Pump

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CAUTION: Make sure connecting rods and rod caps are numbered, to retain correct orientation.
Fig 36: Removing Bolts And Connecting Rod Caps
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38. Remove the bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is at bottom dead center.
    • Remove and discard the bolts.
CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
Fig 37: Removing Piston And Rod Assembly
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39. Remove the piston and rod assembly.
    • Using the special tools, guide the piston and rod assembly out of the cylinder.
40. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
41. Remove and discard the 12 crossmounted bolts.
    Fig 38: Removing Crossmounted Bolts

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42. Remove and discard the bolts.
    Fig 39: Removing Bolts

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43. Remove the main bearing cap dowel pins.
    Fig 40: Removing Main Bearing Cap Dowel Pins

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44. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 41: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Thrust Washer

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45. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 42: Removing Crankshaft And Crankshaft Main Bearings From Cylinder Block

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