Part 2

35. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.





36. Disconnect the radio capacitor electrical connector.





37. Disconnect the 4 fuel injector electrical connectors.
^ Detach the 2 wiring harness retainers and remove the wiring harness assembly.





38. Remove the fuel rail insulator.





39. Remove the nut and the radio capacitor.





40. Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.





41. Remove the 8 bolts (3 shown) and position the intake manifold aside.

42. 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.





Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.





43. Remove the EGR tube.





44. Disconnect the coolant hose.





45. Disconnect and remove the coolant hose.





46. Disconnect and remove the 2 coolant hoses.





47. Remove the bolt and the KS.





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





49. If equipped, remove the block heater.





50. Remove the oil level indicator.

51. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.





Remove the 4 bolts and the 4 coil-on-plugs.





52. Remove the 12 retainers and the valve cover.





53. Remove the bolts and the CKP sensor.

54. CAUTION: 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.

55. CAUTION: The Camshaft Alignment Plate 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.





56. Remove the engine plug bolt.





57. 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 disassembly.

Install the Crankshaft TDC Timing Peg.





58. NOTICE: The crankshaft must remain in the 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 special 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.

Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
^ Remove and discard the crankshaft pulley bolt and washer.
^ Remove the crankshaft pulley.
^ Remove the diamond washer and discard.

59. CAUTION: 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.





60. Remove the 22 bolts and the engine front cover.





61. 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.





62. Remove the 2 bolts and timing chain tensioner.





63. Remove the RH timing chain guide.





64. Remove the timing chain.





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

66. CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.





Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.

67. CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.





Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.





68. Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.

69. NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.





Remove the oil pump chain and sprockets.
1 Remove the bolt.
2 Remove the chain and sprockets.





70. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.





71. Remove the bolt and the VCT solenoid.





72. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.

73. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

NOTE: Mark the location and orientation of each camshaft bearing cap.





Remove the camshafts from the engine.
^ Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
^ Remove the camshaft bearing caps.
^ Remove the camshafts.

74. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650mm.

Remove and inspect the valve tappets.





75. Remove the cylinder head.
^ Remove and discard the cylinder head bolts.
^ Remove the cylinder head.
^ Remove and discard the cylinder head gasket.

76. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.





77. Remove the cylinder head alignment dowels.





78. Remove the bolts and the oil pan.





79. Remove the bolts and the rear crankshaft seal.





80. Remove the bolts, oil pump pickup tube and gasket.
^ Discard the gasket.





81. Remove the bolts and the oil pump.