Engine Mechanical: Mechanical: Engine-3.8L: Disassembly: Engine

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 bolts and the LH engine support insulator.
   Fig 4: Removing LH Engine Support Insulator

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2. Remove the bolts and the RH engine support insulator.
   Fig 5: Removing RH Engine Support Insulator

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3. Remove the special tool.
   Fig 6: Removing Special Tool

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4. Remove the special tool.
   Fig 7: Removing Special Tool

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5. Remove the bolt and the oil level indicator and tube. Discard the O-ring.
   Fig 8: Removing Oil Level Indicator And Tube

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6. Remove the bolts and the LH exhaust manifold. Discard the gasket.
   Fig 9: Removing LH Exhaust Manifold

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7. Disconnect the exhaust gas recirculation (EGR) tube.
   Fig 10: Disconnecting Exhaust Gas Recirculation (EGR) Tube

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8. Remove the EGR tube.
   Fig 11: Removing EGR Tube

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9. Remove the nuts and the RH exhaust manifold. Discard the gasket.
   Fig 12: Removing Nuts And RH Exhaust Manifold

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10. Disconnect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors.
    Fig 13: Disconnecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors

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11. Position the RH spark plug wires aside.
    Fig 14: Removing RH Spark Plug Wires

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12. Position the LH spark plug wires aside.
    Fig 15: Removing LH Spark Plug Wires

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13. Disconnect the ignition coil and the radio interference capacitor electrical connectors.
    Fig 16: Disconnecting Ignition Coil And Radio Interference Capacitor Electrical Connectors

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14. Remove the positive crankcase ventilation (PCV) tube.
    Fig 17: Removing Positive Crankcase Ventilation (PCV) Tube

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15. Disconnect the vacuum hoses.
    Fig 18: Disconnecting Vacuum Hoses

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16. Disconnect the differential pressure feedback EGR system electrical and vacuum connections.
    Fig 19: Disconnecting Differential Pressure Feedback EGR System Electrical And Vacuum Connections

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17. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 20: Disconnecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections

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NOTE: Record the location of the long bolts and the short bolts.
Fig 21: Removing Upper Intake Manifold And Upper Intake Manifold Gasket
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18. Remove the upper intake manifold and the upper intake manifold gasket.
19. Remove the fuel injection supply manifold and the fuel injectors. For additional information, refer to REMOVAL & INSTALLATION .
20. Disconnect the cylinder head temperature (CHT) sensor.
    Fig 22: Disconnecting Cylinder Head Temperature (CHT) Sensor

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21. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 23: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector

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22. Disconnect the engine oil pressure sender electrical connector.
    Fig 24: Disconnecting Engine Oil Pressure Sender Electrical Connector

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23. Remove the pin-type retainer.
    Fig 25: Removing Pin-Type Retainer

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24. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 26: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

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25. Remove the engine wiring harness.
    Fig 27: Removing Engine Wiring Harness

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26. Remove the stud bolt.
    Fig 28: Removing Stud Bolt

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27. Remove the heater water outlet tube.
    Fig 29: Removing Heater Water Outlet Tube

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NOTE: Record the location of the long bolts and the short bolts.
Fig 30: Removing Lower Intake Manifold And Intake Manifold Gasket
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28. Remove the lower intake manifold and the intake manifold gasket.
29. Remove the accessory drive belt.
    Fig 31: Removing Accessory Drive Belt

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30. Remove the water pump pulley.
    Fig 32: Removing Water Pump Pulley

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31. Remove the A/C compressor bracket.
    Fig 33: Removing A/C Compressor Bracket

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32. Using the special tool, remove the power steering pump pulley.
    Fig 34: Removing Power Steering Pump Pulley

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33. Remove the power steering pump bracket.
    Fig 35: Removing Power Steering Pump Bracket

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34. Remove the bolts and the generator mounting bracket.
    Fig 36: Removing Bolts And Generator Mounting Bracket

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35. Remove the crankshaft pulley bolt.
    Fig 37: Removing Crankshaft Pulley Bolt

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36. Using the special tool, remove the crankshaft pulley.
    Fig 38: Removing Crankshaft Pulley

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37. Remove the RH and the LH valve covers.
    Fig 39: Removing RH And LH Valve Covers

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38. Inspect the valve cover gaskets. Install new gaskets if necessary.
    Fig 40: Inspecting Valve Cover Gaskets

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39. Remove the bolts and the oil pan.
    Fig 41: Removing Bolts And Oil Pan

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CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location
40. Remove the LH rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms.
       Fig 42: Removing LH Rocker Arms

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41. Remove the LH push rods.
    Fig 43: Removing LH Push Rods

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NOTE: Record the location of the long bolts and the short bolts.
Fig 44: Removing LH Cylinder Head Bolts
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42. Remove and discard the LH cylinder head bolts.
43. Remove the LH cylinder head and gasket. Discard the gasket.
    Fig 45: Removing LH Cylinder Head And Gasket

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44. Remove the RH rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms.
       Fig 46: Removing RH Rocker Arms

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45. Remove the RH push rods.
    Fig 47: Removing RH Push Rods

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NOTE: Record the location of the long bolts and the short bolts.
Fig 48: Removing RH Cylinder Head Bolts
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46. Remove the discard the RH cylinder head bolts.
47. Remove the RH cylinder head and gasket. Discard the gasket.
    Fig 49: Removing RH Cylinder Head And Gasket

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48. Remove the camshaft synchronizer. For additional information, refer to REMOVAL & INSTALLATION .
49. Remove the bolts and the crankshaft position sensor.
    Fig 50: Removing Bolts And Crankshaft Position Sensor

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50. Using the special tool, remove the crankshaft front seal.
    Fig 51: Removing Crankshaft Front Seal

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51. Remove the bolts and the front cover assembly and gasket.
    Fig 52: Removing Front Cover Assembly And Gasket

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52. Remove the camshaft position sensor drive gear.
    1. Remove the bolt.
    2. Remove the camshaft position sensor drive gear.
       Fig 53: Removing Camshaft Position Sensor Drive Gear

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53. Compress and install a retaining pin to hold the timing chain tensioner.
    Fig 54: Installing Retaining Pin To Hold Timing Chain Tensioner

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54. Remove the camshaft sprocket, the crankshaft sprocket and the timing chain as an assembly.
    Fig 55: Removing Camshaft Sprocket, Crankshaft Sprocket And Timing Chain

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55. Remove the timing chain tensioner.
    1. Remove the bolts.
    2. Remove the timing chain tensioner.
       Fig 56: Removing Timing Chain Tensioner

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56. Remove the engine dynamic balance shaft.
    • Remove the bolts.
    • Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
      Fig 57: Removing Engine Dynamic Balance Shaft

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57. Remove the valve tappets.
    1. Remove the bolts.
    2. Remove the tappet guide plates and retainers.
    3. Remove the valve tappets.
       Fig 58: Removing Valve Tappets

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58. Remove the engine balance shaft drive gear.
    1. Remove the camshaft keyway.
    2. Remove the gear.
       Fig 59: Removing Engine Balance Shaft Drive Gear

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59. Remove the camshaft.
    1. Remove the bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
       Fig 60: Removing Camshaft

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60. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
       Fig 61: Removing Bearing Covers

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61. Remove the oil pump screen cover and tube.
    Fig 62: Removing Oil Pump Screen Cover And Tube

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62. Remove the oil pan bridge and baffle assembly.
    Fig 63: Removing Oil Pan Bridge And Baffle Assembly

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CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct location.
CAUTION: Each connecting rod and connecting rod cap are matched sets. They will fit together only one way. Mark them before removing.
CAUTION: Care should be taken not to damage the connecting rod and the connecting rod cap fractured joint face surface or engine damage may occur.
NOTE: 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 and following the manufacturer's instructions.
63. Remove the pistons.
    1. Make sure the piston being removed is at the bottom of the cylinder bore.
    2. Remove the bolts.
    3. Remove the connecting rod cap and the lower connecting rod bearing.
    CAUTION: Be careful to avoid damage to the cylinder wall when removing the piston
    Fig 64: Removing Piston And Connecting Rod Out Of Cylinder
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    4. Push the piston and the connecting rod out of the cylinder.
64. Repeat the removal steps for the remaining pistons.
CAUTION: The crankshaft main bearings and the main bearing caps are matched to the crankshaft journals. Make sure the components are marked for position.
NOTE: The crankshaft main bearing located at the rear main bearing cap is the thrust bearing.
65. Remove the four main bearing caps and lower crankshaft main bearings.
    1. Remove the stud bolts.
    2. Remove the main bearing cap and the lower crankshaft main bearing.
       Fig 65: Removing Main Bearing Cap And Lower Crankshaft Main Bearing

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66. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the crankshaft lower main bearings.
CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed
Fig 66: Removing Crankshaft & Crankshaft Rear Seal
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67. Remove the crankshaft and the crankshaft rear seal.
NOTE: For ease in assembly, record the location of the crankshaft upper thrust bearing.
Fig 67: Removing Crankshaft Upper Main Bearings And Crankshaft Upper Thrust Bearing
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68. Remove the crankshaft upper main bearings and the crankshaft upper thrust bearing.
69. Using the camshaft bearing service set, remove the camshaft bearings.
    Fig 68: Removing Camshaft Bearings

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70. Using the camshaft bearing service set, remove the engine dynamic balance shaft bearings.
    Fig 69: Removing Engine Dynamic Balance Shaft Bearings

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71. If equipped, remove the engine block heater. For additional information, refer to ENGINE COOLING .
NOTE: For cleaning purposes, the plugs should be removed.
72. If necessary, remove the following:
    1. the cylinder block dowels.
    2. the oil gallery plugs.
    3. the water jacket plugs.
       Fig 70: Removing Cylinder Block Dowels, Oil Gallery Plugs And Water Jacket Plugs

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