Part 2
Engine
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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.
30. Remove the nut and the Heated Oxygen Sensor (HO2S) electrical connector bracket.
31. Loosen the 12 retainers and remove the valve cover.
- Discard the gasket.
32. Remove the 1 engine mount stud.
33. Remove the 4 bolts and coolant pump pulley.
34. Remove the 9 bolts and the timing belt cover.
35. Remove the 3 bolts and the engine mount bracket.
36. NOTICE: Only rotate the crankshaft in a clockwise direction.
Using the crankshaft pulley bolt, turn the crankshaft clockwise until the markings on the camshaft phaser and sprockets are at the 11 o'clock position as shown.
37. Remove the engine plug bolt.
38. NOTE: The Crankshaft Top Dead Center (TDC) Timing Pin 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.
Install the Crankshaft TDC (Top Dead Center) Pin.
39. NOTE: Only rotate the crankshaft clockwise direction.
Rotate the crankshaft until it contacts the Crankshaft TDC (Top Dead Center) Pin.
40. Using the Strap Wrench, remove the crankshaft pulley bolt and the crankshaft pulley.
- Discard the crankshaft pulley bolt.
41. Remove the 3 bolts and the lower timing belt cover.
42. Install the VCT (Variable Camshaft Timing) Alignment Tool.
43. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.
Remove the timing belt.
1. Rotate the timing belt tensioner clockwise.
2. Align the 2 holes on the tensioner and install a small screwdriver or holding pin.
- Remove the timing belt.
44. Remove the 4 bolts and the timing belt cover backplate.
45. Remove the crankshaft sprocket gear.
46. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the crankshaft front oil seal.
47. Remove the bolt and the timing belt tensioner.
48. Remove the 6 bolts and the coolant pump.
- Discard the gasket.
49. Remove the 4 spark plugs.
50. Remove the VCT (Variable Camshaft Timing) Alignment Tool.
51. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Remove the 2 camshaft phaser and sprocket plugs.
52. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Remove the 2 bolts and the camshaft phaser and sprockets.
53. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the 2 camshaft oil seals.
54. NOTE: Note the position of each component before removal.
Remove the bolts for the camshaft bearing caps and VCT (Variable Camshaft Timing) bridge in the sequence shown.
55. Remove the VCT (Variable Camshaft Timing) bridge O-ring seal.
- Inspect and replace the VCT (Variable Camshaft Timing) bridge O-ring seal, if necessary.
56. NOTICE: Do not pry on camshafts when removing or damage to the camshafts may occur.
Remove the 2 camshafts from the cylinder head.
57. If necessary, remove the 2 bolts and the camshaft trigger wheels.
58. 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.
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.
Remove and inspect the valve tappets.
59. Remove the Crankshaft TDC (Top Dead Center) Pin.
60. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.
Remove the 10 cylinder head bolts in the sequence shown.
- Remove the cylinder head.
- Discard the cylinder head bolts and gasket.
61. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
62. Remove the cylinder head alignment dowels.
63. Remove the 13 bolts from the oil pan.
64. Using the pry pads, remove the oil pan.
65. Remove the 6 bolts and the crankshaft rear seal.
66. Remove the 3 bolts and the oil pump screen and pickup tube.
- Inspect and replace the O-ring seal, if necessary.
67. Remove the 4 bolts and the windage tray.
68. NOTE: Mark the location of the 3 different length bolts.
Remove the 8 bolts and the oil pump.
- Discard the gasket.
69. 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.
70. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
Remove the bolts and the connecting rod cap.
71. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
72. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
73. NOTE: Mark the position of the parts, so they can be installed in their original positions.
Remove the connecting rod bearings from the connecting rod and cap.
74. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.
Remove the 10 bolts in the sequence shown and the main bearing beam.
75. 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.
76. Remove the crankshaft from the engine block.
77. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
78. Inspect the cylinder block and main bearing beam.
79. Inspect the pistons and connecting rods.