Part 2

31. Remove the 3 bolts and the coolant pump.





32. Disconnect the coolant hose.





33. Disconnect the EGR coolant hose and the heater hose.
^ Remove the heater hoses, EGR coolant hose and the motor electronics coolant pump and hoses as a assembly.





34. Remove the 3 bolts and the thermostat housing.





35. Disconnect the coolant hose.





36. Disconnect and remove the coolant hose.





37. Remove the 2 bolts, the nut and the vacuum pump assembly.





38. Remove the bolt and the KS.





39. Remove the 8 bolts and the crankcase vent oil separator.

40. NOTE: Spin-on oil filter adapter shown, element oil filter adapter similar.





Remove the 4 bolts and the oil filter adapter.
^ Discard the gasket.





41. If equipped, remove the block heater.





42. Remove the crankshaft vent tube.





43. Remove the engine cover studs.





44. Remove the 4 stud bolts and the coil-on-plugs from the valve cover.





45. Remove the oil level indicator.

46. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.





Remove the spark plugs and the CHT sensor.
^ Discard the CHT sensor.





47. Remove the bolts and the valve cover.

48. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.





Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
^ The hole in the crankshaft pulley should be in the 6 o'clock position.

49. NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.





Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.





50. Remove the engine plug bolt.

51. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.





Install the Crankshaft TDC Timing Peg.

52. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.





Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
^ Remove and discard the crankshaft pulley bolt and washer.
^ Remove the crankshaft pulley.
^ Remove the diamond washer and discard.

53. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.





Using the Oil Seal Remover, remove the crankshaft front oil seal.





54. Remove the 2 bolts and the CKP sensor.





55. Remove the bolts and the engine front cover.





56. Compress the timing chain tensioner in the following sequence.
1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.





57. Remove the 2 bolts and the timing chain tensioner.





58. Remove the RH timing chain guide.





59. Remove the timing chain.





60. Remove the bolts and the LH timing chain guide.