Disassembly

Special Tools:

1. Remove engine as described and install engine on engine stand, following manufacturer's instructions using Rotunda Powertrain Lift 014-00765 and Rotunda Universal Powertrain Removal Bracket 014-00766 or equivalents.
2. Release front end accessory drive belt tension by rotating drive belt tensioner counterclockwise.
3. Remove drive belt.

2 Of 2:

4. Remove A/C compressor mounting bolts from cylinder block. Remove A/C compressor.

Generator And Bracket, Removal:

5. Remove Generator (GEN) from generator bracket.
6. Remove generator bracket from cylinder block.
7. Remove Rotunda 3.4L-SHO Engine Lifting Brackets 303-F055 (014-00797) or equivalent from RH and LH cylinder heads.
8. Rotate water pump drive belt tensioner clockwise to release water pump drive belt tension and remove water pump drive belt. Carefully release drive belt tensioner.
9. Remove three retaining bolts and water pump drive pulley from LH intake camshaft.








10. Remove oil lever indicator, oil level indicator tube and O-ring from LH cylinder head and cylinder block.
11. Disconnect the main emission vacuum supply hose from the surge tank vacuum fitting, secondary air injection diverter valve and EGR valve (EGR-9).
12. Disconnect engine control sensor wiring from EGR backpressure transducer, EGR vacuum regulator solenoid and secondary air injection control solenoid vacuum valve.
13. Remove the two retaining bolts for the transducer mounting bracket from the surge tank.
14. Disconnect EGR pressure sensor valve hoses from EGR valve to exhaust manifold tube and remove transducer mounting bracket from engine.





15. Remove EGR valve to exhaust manifold tube from EGR valve and exhaust manifold.








16. Remove the two intake manifold supports from the surge tank and cylinder head





17. Remove retaining bolts and surge tank stay from front of surge tank.
18. Remove bolt, nuts and serge tank stay from rear of surge tank.
19. Loosen intake air connector hose clamps and remove surge tank from engine.
20. Disconnect wiring connections for the engine control sensor wiring from the Idle Air Control valve (IAC) valve and throttle position sensor UP sensor.
21. Remove water bypass hoses from the throttle body.
22. If required, remove idle air control valve and gasket from the engine air inlet connector. Discard gasket.





23. If required, remove throttle body retaining bolts and throttle body from engine air inlet connector. Discard gasket.





24. Remove two stud bolts and engine air inlet connector from intake manifold.
25. Remove intake manifold to lower Intake Manifold (IMRC) retaining bolts.
26. Remove RH and LH intake manifolds from lower Intake Manifold (IMRC).
27. Disconnect engine control sensor wiring from the following components:
- water temperature indicator sender unit
- engine coolant temperature sensor (ECT sensor)
- ignition coils
- radio ignition interference capacitor
- fuel injectors
- Camshaft Position Sensor (CMP sensor)





- oil pressure sensor
- crankshaft position sensor (CKP sensor)
- engine control sensor extension wiring
- intake manifold runner control (IMRC) deactivation motor
28. Remove engine control sensor wiring from engine assembly.





29. Remove exhaust air supply tube from exhaust manifolds and secondary air injection diverter valve.
30. Remove two retaining bolts and secondary air injection diverter valve from exhaust air supply valve mounting bracket if required.
31. Remove exhaust manifolds and exhaust manifold gaskets from cylinder heads.
32. Remove Positive Crankcase Ventilation Valve (PCV valve) from oil separator crankcase ventilation tube.
33. Disconnect intake manifold runner control deactivation cable from lower Intake Manifold (IMRC). Remove cable from bracket and position aside.

Intake Air Connector Hose Clamp Orientation:

34. Remove lower intake manifold, fuel injectors and fuel injection supply manifold as an assembly from cylinder heads.
35. Remove intake manifold gaskets from cylinder heads and discard.
36. Loosen upper radiator hose spring clamp. Remove upper radiator hose from water crossover.
37. Remove retaining bolts and water crossover from RH cylinder head.





38. Loosen oil cooler to water pump and heater core to water pump hose spring clamps. Remove oil cooler to water pump hoses from water pump.
39. Remove water pump to LH cylinder head retaining bolts and remove water pump.
40. Remove RH and LH valve covers from cylinder head.
41. Remove spark plugs from cylinder heads.
42. Remove retaining nut and power steering pump pulley.





43. Remove power steering pump and power steering pump support from engine.
44. Loosen crankshaft pulley retainer bolt at crankshaft.





45. Remove crankshaft pulley from crankshaft using Steering Wheel Puller 211-014 (T67L-3600-A).
46. If necessary, remove camshaft position sensor from LH cylinder head and crankshaft position sensor from engine front cover.





47. Remove oil pan drain plug and drain engine oil. Reinstall oil pan drain plug with new oil pan drain plug gasket. Tighten to 20-34 Nm (15-25 ft. lbs.).
48. Remove oil filter, engine oil cooler, oil pressure sensor and oil filter adapter from cylinder block.
49. Remove oil pan and residual gasket sealing material from lower cylinder block.





50. Remove drive belt idler pulleys from engine front cover, if required.
51. If required, use Locknut Pin Remover 211-S060 (T78P-3504-N) to remove crankshaft front seal from engine front cover.

Fig. 11 Engine Front Cover Removal:

52. Remove retaining bolts and engine front cover.
53. Remove crankshaft position sensor pulse ring from crankshaft.

Crankshaft & Oil Pump Timing Mark Alignment:

54. Rotate the crankshaft to position the No. 1 piston at top-dead-center (TDC) by aligning the crankshaft keyway groove with the oil pump mark.
55. Verify the timing marks on the camshaft sprockets are on top. If the timing marks on the camshaft sprockets are not up, rotate the crankshaft one complete revolution.

(Part 1 Of 2):

(Part 2 Of 2):

56. Remove retaining bolts, timing chain guides, timing chain tensioner arm and timing chain tensioner.
57. Using a small screwdriver, release the timing chain tensioner ratchet/PEMI mechanism through the access hole in the timing chain tensioner. Compress timing chain tensioner rack and piston into the tensioner housing by inserting a small wire into the top of piston and gently unseat oil check ball. Compress timing chain tensioner by hand.

Tensioner Lock Pin Installation:

58. NOTE: Timing chain tensioner must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioner prior to installation may cause damage to engine.

With the tensioner rack and piston compressed, install a 1.5mm (0.060 inch) drill bit or wire into the small hole above the ratchet, engaging the lock groove in the rack of the timing chain tensioner.





59. Remove retaining bolt, engine balance shaft driven gear and balance shaft sprocket key from engine dynamic balance shaft.





60. Remove three retaining bolts and balance shaft thrust plate from cylinder block.





61. Thread Balance Shaft Remover/Replacer 303-549 (T96P-6A333-AH) into balance shaft. Thread Impact Slide Hammer 100-001 (T50T-100-A) into remover/replacer. Pull balance shaft and front bearing out with slide hammer.





62. Thread Balance Shaft Rear Bearing Remover 303-550 (T96P-6A333-BH) onto Balance Shaft Remover/ Replacer 303-549 (T96P-6A333-AH). Insert Remover through inside diameter of rear bearing. Seat tool into bearing inside diameter before pulling. Pull bearing out with Impact Slide Hammer 100-001(T50T-100-A).





63. Remove timing chain sprocket tensioners from cylinder heads.

64. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to make sure that they are assembled in their original positions. If removed, keep camshaft journal caps from each cylinder head together. Do not mix with camshaft journal caps from another cylinder head.

CAUTION: Remove the cylinder head camshaft journal thrust caps first to make sure damage to the cylinder head camshaft journal thrust caps does not occur.

Remove cylinder head camshaft journal thrust cap retaining bolts and thrust caps from cylinder head.

Camshaft Journal Cap Bolt Loosening Sequence:

65. Loosen remaining cylinder head camshaft journal cap bolts in sequence shown 7-8 revolutions in several passes to allow camshafts to be raised from cylinder head. Do not remove retaining bolts completely.
66. Remove timing chain crankshaft sprocket.

Cylinder Head Bolt Loosening Sequence:

67. Remove cylinder head retaining bolts and washers in sequence shown.

68. NOTE: Cylinder heads should not be set on cylinder head face. Protect cylinder head face surface to avoid scratches and dents on cylinder head face sealing surfaces.

Remove cylinder heads from cylinder block.
69. Remove cylinder head gasket from cylinder block.
70. If required, disassemble cylinder heads.








71. Remove retaining bolts, wire clamp and water outlet from cylinder block. Discard water outlet gasket.





72. Disconnect engine control sensor extension wiring from knock sensors (KS). Remove knock sensors from cylinder block.





73. Remove retaining bolts and nuts, crankcase vent oil separator and oil separator to cylinder block gasket from cylinder block. Discard oil separator to cylinder block gasket.
74. Turn engine over on engine stand.
75. Remove oil pump screen cover and tube and oil pump inlet tube gasket from oil pump.





76. Remove retaining nuts and oil pan baffle from lower cylinder block retaining studs.

Fig. 18 Oil Pump Bolt Removal Sequence:

77. Remove oil pump retaining bolts in sequence shown. Remove oil pump from cylinder block. Inspect oil pump.

78. CAUTION: Piston, pin and rings, connecting rods and connecting rod bearings should be numbered to ensure they are assembled in their original positions.

NOTE: Before removing piston, pin and rings, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer 303-016 (T64L-6011-EA).

Turn crankshaft until piston, pin and ring to be removed is at the high point of its travel.

79. NOTE: Mark position of connecting rod cap to connecting rod for aid in reassembly.

If more than one piston, pin and ring is being removed, identify the piston, pin and rings, connecting rods and connecting rod caps for cylinder position.





80. Remove the connecting rod cap retaining bolts, connecting rod cap and lower connecting rod bearing. Keep connecting rod cap and lower connecting rod bearing together. Using Connecting Rod Guide Tool 303-462 (T94P-6136-AH) installed into the connecting rod bolt holes, push the piston, pin and ring, connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.

81. CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or engine damage may occur.

CAUTION: Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.






Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at least twice and must be discarded. Using a hammer and punch, drive bolts from bolt holes.
82. Using a new connecting rod bolt, attach connecting rod cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
83. If piston ring replacement is required replace piston rings.
84. If required, remove piston, pin and rings from connecting rods.

85. CAUTION: Avoid scratching or damaging the oil seal sealing surfaces on crankshaft and cylinder block.





Position Rear Crankshaft Seal Remover 303-519 (T95P-6701-EH) on end of crankshaft. Rotate seal remover clockwise to thread seal remover into seal lip until tight.






86. Install Impact Slide Hammer 100-001 (T50T-100-A) into seal remover, and pull seal from crankcase bore.





87. Using removal sequence, remove lower cylinder block retaining bolts.
88. Remove lower cylinder block from upper cylinder block.

89. NOTE: If bearings are to be reused, mark position of upper and lower crankshaft main bearings and crankshaft thrust washers.

Remove lower crankshaft main bearings and crankshaft thrust washers from lower cylinder block.

90. CAUTION: When removing crankshaft, use care not to damage any crankshaft journal bearing surfaces.

Remove crankshaft.








91. Remove upper crankshaft main bearings and crankshaft thrust washer from cylinder block.
92. If necessary, remove crankshaft key from crankshaft keyway.
93. Remove pipe plugs and alignment dowels from cylinder block as necessary to clean cylinder block and debris from oil passages.
94. Inspect crankshaft and cylinder block. Replace crankshaft and cylinder block as required.