Part 2

Engine














NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

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, can cause engine failure.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

36. Disconnect the fuel injection pump electrical connector.
- Remove the fuel injection pump insulator.






37. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.
Loosen the 2 high pressure fuel tube flare nuts.

- Remove the 2 bolts and the high pressure fuel tube.

- Discard the high pressure fuel tube.






38. NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

Remove the 5 bolts and the fuel rail.
- Discard the bolts.






39. Remove any of the fuel injectors that remained in the fuel rail.





40. Using the Slide Hammer and the Fuel Injector Remover, remove the fuel injectors that remained in the cylinder head.





41. Remove and discard the fuel injector clips.





42. Discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.





43. NOTICE: Do not attempt to cut the lower Teflon(R) seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.
Pull the lower Teflon(R) seal away from the injector with narrow tip pliers.






44. Carefully cut and discard the lower fuel injector Teflon(R) seals.





45. Remove the 3 bolts and the thermostat housing.





46. Remove the 3 bolts and the brake vacuum pump.





47. Remove the 2 bolts and the fuel injection pump bracket.





48. Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.
- Remove the fuel injection pump.






49. Remove and discard the fuel injection pump O-ring seal.





50. Slide the fuel injection pump tappet out of the fuel injection pump housing.





51. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.





52. Remove the 4 stud bolts and the fuel injection pump housing.





53. Disconnect the 9 wiring harness electrical connectors.
- Detach the 7 retainers and remove the wiring harness from the engine.






54. Detach the 2 retainers and slide the vacuum hose assembly off of the valve cover tab.





55. Remove the oil level indicator.
- Remove the 4 bolts and the 4 coil-on-plugs.

- Remove the nut, bolt and CAC (Charge Air Cooler) intermediate tube mounting bracket.






56. Loosen the 14 valve cover retainers and remove the valve cover.
- Discard the valve cover gasket.






57. NOTE: The VCT (Variable Camshaft Timing) solenoid seals should only be replaced if they are damaged.
Remove any damaged VCT (Variable Camshaft Timing) solenoid seals using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Remover and Handle.






58. Remove the 2 bolts and the rear intake camshaft cap.





59. Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.





60. NOTE: Turn the engine in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC (Top Dead Center) marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.






61. Remove the engine plug bolt.





62. Install the Crankshaft TDC (Top Dead Center) Timing Peg.





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

NOTE: The engine front cover is shown removed in graphic for clarity.

Rotate the crankshaft slowly clockwise until the crankshaft contacts the Crankshaft TDC (Top Dead Center) Timing Peg.
- The TDC (Top Dead Center) marked tooth on the crankshaft pulley will align with the center line of the CKP (Crankshaft Position) sensor.






64. NOTICE: The Camshaft Alignment Tool 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 Camshaft Alignment Tool cannot be installed, remove the TDC (Top Dead Center) Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown.
- Tighten the retainer.






65. NOTICE: The crankshaft must remain in the TDC (Top Dead Center) 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 Strap Wrench 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 Strap Wrench 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.






66. If the diamond washer did not come off with the crankshaft pulley, remove the washer from the crankshaft and discard.





67. 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.






68. Remove the 2 bolts and the CKP (Crankshaft Position) sensor.





69. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Remove the 20 bolts, 2 stud bolts and the engine front cover.
- Clean and inspect the mounting surfaces of the engine and the front cover.






70. NOTICE: Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.