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.

All engines

61. Remove the 4 bolts and the fuel rail and injectors as an assembly.





62. Remove the 3 thermostat housing-to-lower intake manifold bolts.
- Remove the thermostat housing and discard the gasket.






63. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the 10 bolts and the lower intake manifold.
- Discard the gaskets.






64. Disconnect and remove the CHT (Cylinder Head Temperature) sensor jumper harness.





65. Remove the bolt and the LH CMP (Camshaft Position) sensor.





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





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

If equipped, remove the 6 bolts (4 shown) and the oil cooler.
- Discard the oil cooler and the gaskets.






68. NOTE: Engine without oil cooler shown, engine with oil cooler similar.
Remove the 3 bolts and the oil filter adapter.

- Discard the gasket.






69. Remove the EOP (Engine Oil Pressure) switch.





70. NOTE: LH shown, RH similar.
Remove the 6 bolts and the 6 coil-on-plugs.






71. Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.






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






73. NOTE: VCT (Variable Camshaft Timing) solenoid seal removal shown, spark plug tube seal similar.
Inspect the VCT (Variable Camshaft Timing) solenoid seals and 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).






74. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.






75. Using the 3 Jaw Puller, remove the crankshaft pulley.





76. Using the Oil Seal Remover, remove and discard the crankshaft pulley front seal.





77. Remove the 2 bolts and the engine mount bracket.





78. NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.






79. Remove the 3 bolts and the engine mount bracket.





80. Remove the 22 engine front cover bolts.





81. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.






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





83. 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.






84. 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.






85. Remove the 3 bolts and the RH VCT (Variable Camshaft Timing) housing.





86. Remove the 3 bolts and the LH VCT (Variable Camshaft Timing) housing.





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

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





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





89. 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.






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





91. Remove the primary timing chain tensioner arm.





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





93. Remove the primary timing chain.





94. Remove the crankshaft timing chain sprocket.





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





96. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





97. NOTE: The VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the LH VCT (Variable Camshaft Timing) assembly bolt and the LH exhaust camshaft sprocket bolt.

- Remove the VCT (Variable Camshaft Timing) assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.






98. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will 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. Remove the 2 bolts and the LH secondary timing chain tensioner.