Part 2

Engine Disassembly (Part 1 of 2)





54. Remove the 4 bolts and the coolant inlet housing.
^ Discard the O-ring seal.





55. Remove the throttle body coolant hose.





56. Remove the 5 bolts and the coolant pump.
^ Discard the gasket.





57. Remove the bolts in the sequence shown and remove the RH valve cover.
^ Discard the gasket.





58. Remove the bolts in the sequence shown and remove the LH valve cover.
^ Discard the gasket.





59. CAUTION: 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, which make leak paths.

Use a plastic scraping tool to clean the surfaces.

Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.





60. Remove the 2 nuts and the EGR tube.
^ Discard the gasket.





61. NOTE: LH shown, RH similar.

Remove the 2 exhaust manifold heat shield stud bolts.





62. NOTE: LH shown, RH similar.

Remove the 8 bolts and the 2 exhaust manifold heat shields.





63. NOTE: LH shown, RH similar.

Remove the bolts, spacers and exhaust manifolds.
^ Discard the gaskets.





64. NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.

Remove and discard the bolt and washer.





65. Using the special tool, remove the crankshaft damper.





66. Using the special tool, remove and discard the front crankshaft seal.





67. Remove the engine front cover bolts in the sequence shown.
^ Remove the engine front cover.
^ Discard the gaskets.





68. CAUTION: 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the sealing surfaces.





69. Remove the 17 bolts and the oil pan.
^ Discard the gasket.





70. CAUTION: Use only hand tools to remove the oil pump screen and tube.

Remove the oil pump screen and tube, and the seal.





71. Remove the 4 bolts and the oil pump.





72. CAUTION: 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, which make leak paths. Use a plastic scraping tool to remove all traces of the sealant.

Remove the bolts in the sequence shown and remove the sump body.





73. Remove the RH and LH VCT bush carriers.
74. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.





75. Make sure the flats of the camshaft are facing upward. If not, repeat the previous step.





76. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the RH cylinder head.





77. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the exhaust camshaft sprocket bolt.





78. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the VCT unit bolt.





79. Remove the RH timing chain tensioner.
1 Push the lever down and install a drill rod to lock the piston.
2 Remove the bolts and the tensioner.





80. Remove the bolt and the RH tensioner arm.





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





82. Remove the RH primary timing chain.





83. Remove the special tool from the RH cylinder head.





84. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the LH cylinder head.





85. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.

Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.





86. Remove the LH timing chain tensioner.
1 Push the lever down and install a drill rod to lock the piston.
2 Remove the 2 bolts and the tensioner.





87. Remove the nut and the LH tensioner arm.





88. Remove the bolt and the LH timing chain guide.





89. Remove the LH primary timing chain.
90. Remove the crankshaft sprocket.





91. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.





92. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
93. Remove the 2 bolts and the LH secondary timing chain tensioner.





94. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.





95. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
96. Remove the 2 bolts and the RH secondary timing chain tensioner.





97. Remove the special tool.





98. CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

Remove the LH camshaft bearing caps.
^ Remove the bolts.
^ Remove the LH camshaft bearing caps.





99. Remove the LH camshafts.





100. CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

Remove the RH camshaft bearing caps.
^ Remove the bolts.
^ Remove the RH camshaft bearing caps.





101. Remove the RH camshafts.

102. CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.

CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.

Record the location of the valve tappets.
Remove the valve tappets.





103. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

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

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

NOTE: RH shown, LH similar.

Remove the RH and LH cylinder head end bolts.
^ Discard the bolts.





104. Remove and discard the bolts from both cylinder heads in the sequence shown.
^ Remove the cylinder heads.
^ Discard the gaskets.

105. CAUTION: 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

CAUTION: 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 head and the cylinder block.
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.

106. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).





107. Remove the bolts and the knock sensor.