Part 2

Engine














NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed. 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: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

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

26. Remove the EGR tube.





27. Remove the radio interference capacitor bracket bolt and position the bracket aside.





28. Disconnect the coolant bypass hose.





29. Remove the 4 bolts and the coolant outlet.





30. Disconnect the coolant bypass hose.





31. Remove the 3 bolts, thermostat housing and thermostat.





32. Remove the 2 bolts, stud bolt and the A/C compressor.





33. Remove the bolt and the KS (Knock Sensor).





34. Remove the 8 bolts and the crankcase vent oil separator.





35. Remove the 3 bolts and the intermediate shaft bracket.





36. Remove the 4 bolts and the ignition coil-on-plugs.





37. NOTICE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Remove the spark plugs and the CHT (Cylinder Head Temperature) sensor.






38. Remove the bolts and the valve cover.





39. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.






40. NOTICE: The Camshaft Alignment Plate 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 Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.






41. Remove the engine plug bolt.





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






43. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) 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 Crankshaft Damper Holding Tool, 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 Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool 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.






44. 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 seal.






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





46. Remove the 22 bolts and the engine front cover.





47. 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.






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





49. Remove the RH timing chain guide.





50. Remove the timing chain.