Part 2

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ENGINE DISASSEMBLY - HYBRID

Part 2

Continued From Part 1 Part 1

CAUTION: 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 you loosen the pulley bolt. 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 may occur.

CAUTION: 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, see the exploded views.






40. 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.

CAUTION: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.






41. Install the special tool in the slots on the rear of both camshafts.

CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.






42. Remove the engine plug bolt.






43. Install the special tool.


NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.






44. Assemble the special tools using 4 hardened washers in the locations shown.






45. Using special tools and an air impact wrench, remove the crankshaft pulley.

- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.

- Remove the diamond washer and discard.

CAUTION: 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 special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

CAUTION: 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.






46. Using the special tool, remove the crankshaft front oil seal.

CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.






47. Remove and discard the crankshaft position (CKP) sensor.


NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment tool supplied with the new part.






48. Remove the bolts and the engine front cover.






49. Remove the timing chain tensioner.
a. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.

b. Remove the bolts and timing chain tensioner.






50. Remove the RH timing chain guide.






51. Remove the timing chain.







52. Remove the bolts and the LH timing chain guide.






53. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.

CAUTION: Do not rely on the camshaft alignment plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.






54. Remove the oil pump chain tensioner.
a. Release the tension on the tensioner spring.

b. Remove the tensioner and the shoulder bolts.






55. Remove the oil pump chain and sprockets.
a. Remove the bolt.

b. Remove the chain and sprockets.


NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.






56. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.






57. Remove the camshafts from the engine.

- Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
- Remove the camshaft bearing caps.
- Remove the camshafts.

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

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






58. Remove the cylinder head.

- Remove and discard the cylinder head bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.






59. Remove the cylinder head alignment dowels.






60. Remove the bolts and the oil pan.






61. Remove the bolts and the rear crankshaft seal.






62. Remove the bolts, oil pump pickup tube and gasket.






63. Remove the bolts and the oil pump.






64. Remove the bolts and the block-off plate.