Removal

Removal







CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.


1. Remove the lower intake manifold. Service and Repair
2. Remove the roller followers. Service and Repair
3. Remove the fan shroud. Service and Repair
4. Remove the belt tensioner. Service and Repair






5. Disconnect the generator electrical connectors.






6. Remove the generator mounting bracket.






7. Remove the bolts and position the accessory bracket aside.






8. Disconnect the crankshaft position (CKP) sensor electrical connector.






9. Remove the electrical harness retainer.






10. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.






11. Disconnect the EGR tube nut.






12. Position the EGR valve bracket aside.






13. Remove the upper water heater hose.

1. Squeeze the heater hose clamp.
2. Remove the heater water hose.






14. Remove the lower heater water hose and position aside.

1. Remove the bolt.
2. Squeeze the hose clamp.
3. Remove the heater water hose and position aside.






15. Disconnect the water bypass hose and position aside.






16. Remove the thermostat housing.






17. Remove the crankcase vent separator spring steel clip and remove the separator.






18. Remove the oil level indicator tube.

19. Remove the exhaust manifolds. Service and Repair






20. Remove the engine wiring harness bolts and position the wiring harness aside.






21. Remove the engine compartment ground strap.






22. Remove the LH hydraulic chain tensioner.






23. Remove the bolt.






24. Remove the bolt.






25. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove the cylinder head.

NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the cassette.






26. Remove the eight 12 mm bolts and two 8 mm bolts in the sequence shown and remove the LH cylinder head.

- Discard the head gasket.

27. Remove the RH hydraulic chain tensioner. Service and Repair






28. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Using the special tool, remove bolt and the camshaft sprocket.






29. Remove the bolt.






30. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove the cylinder head.

NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the cassette.






31. Remove the two 8 mm bolts and the eight 12 mm bolts in the sequence shown, and remove the RH cylinder head.

- Discard the head gasket.

32. Inspect the cylinder head and block for flatness.