Steps 51-100
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: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
NOTE: For additional information, refer to the exploded view under the Assembly procedure.
51. Remove the 6 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.
52. Clean and inspect the RH exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.
53. Remove and discard the 6 RH exhaust studs.
54. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.
55. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.
56. Remove the pin-type retainer and the cover.
57. Remove the 2 bolts and the engine lifting eye.
58. Remove the bolt and the upper intake manifold support bracket.
59. Remove the bolt and the RH CMP sensor.
60. Remove the coolant bypass hose from the thermostat housing.
61. Remove the 4 bolts and the fuel rail and injectors as an assembly.
62. Remove the 3 thermostat housing-to-lower intake manifold bolts.
- Remove the thermostat housing and discard the gasket.
63. 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.
Remove the 10 bolts and the lower intake manifold.
- Discard the gaskets.
64. Disconnect and remove the CHT sensor jumper harness.
65. Remove the bolt and the LH CMP sensor.
66. Remove the bolt and the CKP sensor.
67. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, remove the 6 bolts (4 shown) and the oil cooler.
- Discard the oil cooler and the gaskets.
68. NOTE: Engine without oil cooler shown, engine with oil cooler similar.
Remove the 3 bolts and the oil filter adapter.
- Discard the gasket.
69. Remove the EOP switch.
70. NOTE: LH shown, RH similar.
Remove the 6 bolts and the 6 coil-on-plugs.
71. Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.
72. Loosen the bolt, the 8 stud bolts and remove the RH valve cover.
- Discard the gasket.
73. NOTE: VCT solenoid seal removal shown, spark plug tube seal similar.
Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
74. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.
75. Using the 3 Jaw Puller, remove the crankshaft pulley.
76. Using the Oil Seal Remover, remove and discard the crankshaft pulley front seal.
77. Remove the 2 bolts and the engine mount bracket.
78. NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.
79. Remove the 3 bolts and the engine mount bracket.
80. Remove the 22 engine front cover bolts.
81. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.
82. NOTE: Engine equipped with roller timing chain and stamped steel RH timing chain guide shown, other applications similar.
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown.
83. 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.
84. 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.
85. Remove the 3 bolts and the RH VCT housing.
86. Remove the 3 bolts and the LH VCT housing.
Engines equipped with a roller timing chain
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
87. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
88. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
89. Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown.
90. Remove the 2 bolts and the primary timing chain tensioner.
91. Remove the primary timing chain tensioner arm.
92. Remove the 2 bolts and the lower LH primary timing chain guide.
93. Remove the primary timing chain.
94. Remove the crankshaft timing chain sprocket.
95. Remove the 2 bolts and the upper LH primary timing chain guide.
Engines equipped with an inverted tooth timing chain
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
96. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
97. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
98. 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.
99. Remove the 2 bolts and the primary timing chain tensioner.
100. Remove the primary timing chain tensioner arm.
