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

42. 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 seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

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

Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.

- Discard the gasket.





43. Inspect the 2 VCT solenoid seals. Remove any damaged seals.

- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).





44. Inspect the spark plug tube seals. Remove any damaged seals.

- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





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

46. Remove the 2 bolts and the LH exhaust manifold heat shield.





47. Remove the 6 nuts and the LH exhaust manifold.

- Discard the nuts and exhaust manifold gaskets.





48. Clean and inspect the LH exhaust manifold.

49. Remove and discard the 6 LH exhaust manifold studs.





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

Remove the 3 bolts and the 3 RH ignition coil-on-plugs.





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 seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

NOTE: The plastic electrical connector on the VCT 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 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 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 sensors.





61. Remove the 2 bolts and the RH CMP sensors.





62. Remove the bolt and the CKP 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 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 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 assembly as shown.





74. Mark the timing chain link that aligns with the timing mark on the RH intake VCT 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 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 oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Remove the bolt and the LH intake VCT oil control solenoid.





80. NOTE: Removal of the VCT 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 oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Remove the bolt and the RH intake VCT 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 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 assembly bolts.





86. Remove the 2 LH VCT assemblies and secondary timing chain.





87. NOTE: The 2 VCT 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 assembly bolts.





89. Remove the 2 RH VCT 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.