Steps 91-135

Engine













WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

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.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

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: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.

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

All engines

91. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.





92. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.





93. Remove the nut for the high pressure fuel tube from the LH valve cover stud bolt and disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.





94. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the flare nut.

Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails and remove the high pressure fuel tube assembly.





95. Remove the 2 bolts and the fuel injection pump.





96. Remove the fuel injection pump mounting plate.





97. NOTE: Valve cover is removed for clarity.

Remove the fuel injection pump roller tappet.

- Inspect the fuel injection pump roller tappet. For additional information, refer to Fuel Charging and Controls - 3.5L GTDI/3.7L Fuel Injection Pump Roller Tappet Inspection.





NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The following illustrations depict early build components, late build components similar.

98. NOTICE: It is very important to note the routing of the wiring harness on the fuel rails and index-mark the locations of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct wire harness routing and tie strap positioning for installation.

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

Carefully cut and remove the fuel rail wire harness tie straps.





99. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

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

Remove the 6 bolts and the LH fuel rail.





100. Remove the 6 bolts and the RH fuel rail.





101. NOTE: RH shown, LH similar.

Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harnesses.





102. Remove and discard the 6 upper fuel injector O-ring seals.





103. Remove and discard the 6 fuel injector clips.





104. Using the Slide Hammer and the Fuel Injector Remover, remove the 6 fuel injectors.





105. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

Remove the 3 bolts and the 3 RH ignition coils-on-plugs.





106. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

Remove the 3 bolts and the 3 LH ignition coils-on-plugs.





107. Loosen the 10 stud bolts and remove the LH valve cover.
- Discard the gasket.





108. Loosen the 11 stud bolts and remove the RH valve cover.
- Discard the gasket.





109. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.

Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





110. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.





111. Using the 3 Jaw Puller, remove the crankshaft pulley.





112. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





113. Remove the stud bolt and Heated Oxygen Sensor (HO2S) connector bracket from the engine front cover.





114. Remove the 3 bolts and the engine mount bracket.





115. Remove the 22 engine front cover bolts.





116. 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.





117. 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.





118. 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.





119. 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.





120. Remove the 3 bolts and the RH VCT housing.





121. 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.

122. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.





123. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.





124. Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown.





125. Remove the 2 bolts and the primary timing chain tensioner.





126. Remove the primary timing chain tensioner arm.





127. Remove the 2 bolts and the lower LH primary timing chain guide.





128. Remove the primary timing chain.





129. Remove the crankshaft timing chain sprocket.





130. 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.

131. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.





132. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.





133. 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.





134. Remove the 2 bolts and the primary timing chain tensioner.





135. Remove the primary timing chain tensioner arm.