Part 2

Engine














NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

51. NOTICE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

Remove the 3 RH spark plugs.

52. NOTICE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.

NOTICE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT (Variable Camshaft Timing) seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT (Variable Camshaft Timing) seal and VCT (Variable Camshaft Timing) oil control solenoid may occur.

NOTE: The plastic electrical connector on the VCT (Variable Camshaft Timing) oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.

Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.
- Discard the gasket.






53. Inspect the 2 VCT (Variable Camshaft Timing) solenoid seals. Remove any damaged seals.
- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).






54. Inspect the spark plug tube seals. Remove any damaged seals.
- Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Remover and Handle, remove the seal(s).






55. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

56. Remove the 2 bolts and the RH exhaust manifold heat shield.





57. Remove the 6 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.






58. Clean and inspect the RH exhaust manifold.

59. Remove and discard the 6 RH exhaust manifold studs.





60. Remove the 2 bolts and the LH CMP (Camshaft Position) sensors.





61. Remove the 2 bolts and the RH CMP (Camshaft Position) sensors.





62. Remove the bolt and the CKP (Crankshaft Position) sensor.





63. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.


If equipped, remove the oil cooler mounting bolt and the oil cooler.






64. Remove the 5 bolts and the oil filter adapter.
- Discard the gasket.






65. Remove the 22 engine front cover bolts.





66. Using a pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.





67. NOTE: Inspect front cover radial seal and replace if necessary.

NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.

If necessary, using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.






68. Rotate the crankshaft clockwise and align the timing marks on the VCT (Variable Camshaft Timing) assemblies as shown.





69. Remove the 3 bolts and the LH valve train oil tube.





70. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

Install the Camshaft Holding Tool onto the flats of the LH camshafts.






71. Remove the 3 bolts and the RH valve train oil tube.





72. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC (Top Dead Center) position.

Install the Camshaft Holding Tool onto the flats of the RH camshafts.






NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.

73. Mark the timing chain link that aligns with the timing mark on the LH intake VCT (Variable Camshaft Timing) assembly as shown.





74. Mark the timing chain link that aligns with the timing mark on the RH intake VCT (Variable Camshaft Timing) assembly as shown.





75. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.






76. Remove the 2 bolts and the primary timing chain tensioner.





77. Remove the primary timing chain tensioner arm.





78. Remove the 2 bolts and the lower LH primary timing chain guide.





79. NOTE: Removal of the VCT (Variable Camshaft Timing) oil control solenoid will aid in the removal of the primary timing chain.

NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Remove the bolt and the LH intake VCT (Variable Camshaft Timing) oil control solenoid.






80. NOTE: Removal of the VCT (Variable Camshaft Timing) oil control solenoid will aid in the removal of the primary timing chain.

NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Remove the bolt and the RH intake VCT (Variable Camshaft Timing) oil control solenoid.






81. Remove the primary timing chain.





82. Remove the crankshaft timing chain sprocket.





83. NOTICE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.

Remove the bolt and the upper LH primary timing chain guide.






84. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.

NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.






85. Remove and discard the 2 LH VCT (Variable Camshaft Timing) assembly bolts.





86. Remove the 2 LH VCT (Variable Camshaft Timing) assemblies and secondary timing chain.





87. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.

NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.






88. Remove and discard the 2 RH VCT (Variable Camshaft Timing) assembly bolts.





89. Remove the 2 RH VCT (Variable Camshaft Timing) assemblies and secondary timing chain.





90. NOTICE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

Remove the bolt and the RH primary timing chain guide.






91. Remove the 9 bolts and the channel cover plate.
- Discard the gaskets.






Engines with secondary timing chain tensioner removed

NOTICE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed, or damage to the engine may occur.

92. NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Remove the LH exhaust VCT (Variable Camshaft Timing) oil control solenoid.






93. Remove the LH secondary timing chain tensioner shoe.





94. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.





95. NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Remove the RH exhaust VCT (Variable Camshaft Timing) oil control solenoid.






96. Remove the RH secondary timing chain tensioner shoe.





97. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.





All engines

98. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

Remove the Camshaft Holding Tool from the LH camshafts.






99. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Verify the LH camshafts are in the neutral position.






100. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.