Part 3

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.

71. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

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






72. 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.






73. Remove the 2 bolts and the timing chain tensioner.





74. Remove the timing chain tensioner arm.
- Remove the 2 bolts and the timing chain guide.

- Remove the timing chain.






75. Remove the 2 bolts and the intake and exhaust camshaft phaser and sprockets.





76. Remove and discard the 2 washers.





77. Remove the 2 bolts and the 2 VCT (Variable Camshaft Timing) solenoids.





78. Remove the 3 bolts and the front camshaft bearing cap.





79. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

NOTE: Note the position of the camshaft lobes on the No. 1 cylinder for installation reference.

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

Remove the camshafts from the engine.
- Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

- Remove the camshaft bearing caps.

- Remove the camshafts.






80. 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.
Remove the 16 valve tappets.






81. 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 3.650 mm.

Inspect the valve tappets.

82. Remove the 10 bolts and the cylinder head.
- Discard the bolts.






83. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.


84. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

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

85. Remove and discard the head gasket.





86. Remove the 2 cylinder head alignment dowels.





87. Remove the 13 bolts and the oil pan.





88. Remove the 6 bolts and the crankshaft rear seal with retainer plate.





89. Remove the 2 bolts and the oil pump screen and pickup tube.
- Discard the gasket.






90. Remove the oil pump drive chain tensioner.
1. Push the tensioner spring down and release the spring from under the shoulder bolt.

2. Remove the 2 shoulder bolts and the tensioner.
- Remove the oil pump chain.







91. Remove the crankshaft sprocket.





92. Remove and discard the diamond washer.





93. Remove the bolt and oil pump sprocket.





94. Remove the 4 bolts and the oil pump.





95. Make sure the Crankshaft TDC (Top Dead Center) Timing Peg is still installed and the engine is still at TDC.
- If necessary, rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC (Top Dead Center) Timing Peg.






96. Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC (Top Dead Center).





97. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
Remove the 4 bolts and the balance shaft assembly.






98. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.





99. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.

100. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
Remove the 8 bolts and the 4 connecting rod caps.






101. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Remove the 4 piston and rod assemblies from the engine block.






102. Remove the 10 bolts in the sequence shown.
- Remove the main bearing beam.






103. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the main bearings from the main bearing beam.






104. Remove the crankshaft from the engine block.





105. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.






106. Remove the 4 bolts and the 4 engine piston oil coolers.