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
51. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.
52. Remove the RH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.
53. Remove the 4 bolts and the thermostat housing.
- Discard the thermostat housing and coolant inlet tube O-ring seals.
54. Remove the 4 bolts and the coolant pump pulley.
55. Remove the 7 bolts and the coolant pump.
- Discard the coolant pump gasket and coolant pump O-ring seal.
56. Remove the coolant inlet pipe.
- Remove and discard the coolant inlet pipe O-ring seals.
57. Remove the 3 bolts and the coolant crossover manifold assembly.
- Remove and discard the 2 gaskets.
58. Remove the bolt for the high-pressure fuel tube.
59. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube assembly.
60. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the LH fuel rail.
- Discard the bolts.
61. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the RH fuel rail.
- Discard the bolts.
62. NOTE: RH shown, LH similar.
Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harness.
63. Using the Slide Hammer and the Fuel Injector Remover, remove any fuel injectors remaining in the cylinder head.
64. Remove and discard the 6 upper fuel injector O-rings.
65. Remove and discard the 6 fuel injector clips.
66. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and general surrounding area of the fuel rails and fuel injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use the brush to clean the tip of the fuel injector.
Using the Fuel Injector Brush, clean the 6 fuel injector bores in the cylinder heads.
67. Remove the bolt and the fuel injection pump mounting plate.
- Remove and discard the gaskets.
68. 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 LH ignition coil-on-plugs.
69. 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 LH spark plugs.
70. 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 11 stud bolts and remove the LH valve cover.
- Discard the gasket.
71. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
72. Inspect the spark plug tube seals. Remove any damaged seals.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
73. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
74. Remove the 8 nuts and the LH exhaust manifold.
- Discard the nuts and exhaust manifold gasket.
75. Clean and inspect the LH exhaust manifold. For additional information, refer to engine.
76. Remove and discard the 8 LH exhaust manifold studs.
77. 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.
78. 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.
79. Remove the 2 nuts and the engine appearance cover bracket.
80. 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.
81. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
82. Inspect the spark plug tube seals. Remove any damaged seals.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
83. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
84. Remove the 8 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gasket.
85. Clean and inspect the RH exhaust manifold. For additional information, refer to engine.
86. Remove and discard the 8 RH exhaust manifold studs.
87. Remove the 2 bolts and the LH CMP sensors.
88. Remove the 2 bolts and the RH CMP sensors. Remove and discard the CHT sensor
89. Remove the bolt and the CKP sensor.
90. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the threaded shaft and the oil cooler.
- Discard the oil cooler.
91. Remove the 5 bolts and the oil filter adapter.
- Discard the gasket.
92. Remove the 22 engine front cover bolts.
93. Using a suitable pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.
94. NOTE: Inspect and replace the front cover radial seal as necessary.
NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.
Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.
95. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
96. Remove the 3 bolts and the LH valve train oil tube.
97. 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.
98. Remove the 3 bolts and the RH valve train oil tube.
99. 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.
100. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
101. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
102. 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.
103. Remove the 2 bolts and the primary timing chain tensioner.
104. Remove the primary timing chain tensioner arm.
105. Remove the 2 bolts and the lower LH primary timing chain guide.
