Part 2

Engine

71. Remove the bolt and the CKP (Crankshaft Position) sensor.





72. Remove the EOP (Engine Oil Pressure) switch.





73. Remove the 3 bolts and the oil filter adapter.
- Discard the gasket.






74. NOTE: LH shown, RH similar.
Remove the 6 bolts and the 6 coil-on-plugs.






75. Remove the 2 nuts and the wiring harness retaining bracket.





76. Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.






77. Loosen the bolt, 8 stud bolts and remove the RH valve cover.
- Discard the gasket.






78. NOTE: VCT (Variable Camshaft Timing) solenoid seal removal shown, spark plug tube seal removal similar.
Inspect the VCT (Variable Camshaft Timing) solenoid seals and the spark plug tube seals. Remove any damaged seals.

- Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Remover and Handle, remove the seal(s).






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






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





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





82. Remove the 2 bolts and the engine mount bracket.





83. NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.






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





85. Remove the 22 engine front cover bolts.





86. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence.
1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.

2. Remove the engine front cover.






87. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown.





88. 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.






89. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC (Top Dead Center) position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.






90. Remove the 3 bolts and the RH VCT (Variable Camshaft Timing) housing.





91. Remove the 3 bolts and the LH VCT (Variable Camshaft Timing) housing.





NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.

92. Mark the timing chain link that aligns with the timing mark on the RH intake VCT (Variable Camshaft Timing) assembly as shown.





93. Mark the timing chain link that aligns with the timing mark on the LH intake VCT (Variable Camshaft Timing) assembly as shown.





94. 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.






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





96. Remove the primary timing chain tensioner arm.





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





98. Remove the primary timing chain.





99. Remove the crankshaft timing chain sprocket.





100. Remove the bolt and the upper LH primary timing chain guide.





101. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





102. NOTE: The VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the LH VCT (Variable Camshaft Timing) assembly bolt and the LH exhaust camshaft sprocket bolt.

- Remove the LH VCT (Variable Camshaft Timing) assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.






103. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.






104. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Verify the LH camshafts are in the neutral position.






105. Remove the 2 bolts and the LH secondary timing chain tensioner.





106. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the LH camshaft bearing caps.

- Remove the LH camshafts.






107. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





108. NOTE: The VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the RH VCT (Variable Camshaft Timing) assembly bolt and the RH exhaust camshaft sprocket bolt.

- Remove the RH VCT (Variable Camshaft Timing) assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.






109. Remove the Camshaft Holding Tool from the RH camshafts.





110. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Rotate the RH camshafts counterclockwise to the neutral position.






111. Remove the 2 bolts and the RH secondary timing chain tensioner.





112. Remove the bolt and the RH timing chain guide.





113. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the RH camshaft bearing caps.

- Remove the RH camshafts.






114. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

NOTE: LH shown, RH similar.
Remove the valve tappets from the cylinder heads.






115. NOTE: LH shown, RH similar.
Remove and discard the M6 bolt from each cylinder head.






116. NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

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

NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTE: LH shown, RH similar.
Remove and discard the 8 bolts from each cylinder head.
- Remove the cylinder heads.

- Discard the cylinder head gaskets.






117. 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 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: 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 surfaces of both the cylinder heads 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 remaining 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.


118. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to Engine.

119. Remove the coolant inlet tube.
- Remove and discard the O-ring seals.






120. Remove the 2 bolts and the Knock Sensor (KS).





121. Remove the 8 bolts and the coolant pump.





122. Remove the 16 oil pan bolts.





123. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan in the following sequence.
1. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.

2. Remove the oil pan.






124. Remove the 2 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.






125. Remove the 3 bolts and the oil pump.





126. Remove the 8 crankshaft rear seal retainer bolts.





127. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer in the following sequence.
1. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.

2. Remove the crankshaft rear seal retainer.






128. NOTICE: Only use a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.


129. 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.

130. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
Remove the bolts in the sequence shown.

- Remove the main bearing cap support brace.

- Discard the bolts.






131. NOTE: The connecting rod cap bolts are torque to yield. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.

NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and cap.






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

Remove the piston/rod assembly from the engine block.






133. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.

134. NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown.
- Discard the bolts.






135. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the 4 main bearing caps.






136. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.






137. NOTE: Inside shown, outside similar.
Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.






138. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the 4 crankshaft main bearings from the cylinder block.






139. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the 4 crankshaft main bearings from the main bearing caps.






140. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods.

141. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Do not use wire brushes, power abrasive discs or 3M Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean all engine sealing surfaces of the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

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

4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

5. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.