Part 2

DISASSEMBLY (Steps 39-77)

Engine





39. Remove the 2 bolts and the fuel rail with the fuel injectors.





40. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.





41. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.





42. Disconnect and remove the coolant hose.





43. Disconnect the coolant bypass hose.





44. Remove the 4 bolts and the coolant bypass.





45. Disconnect and remove the coolant bypass hose.





46. Remove the bolt and the KS.





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





48. If equipped, remove the block heater.





49. Remove the crankcase vent tube and the coil-on-plugs.





50. CAUTION: 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 sensor.
^ Discard the CHT.





51. Remove the bolts and the valve cover.

52. CAUTION: 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 TDC.
^ The hole in the crankshaft pulley should be in the 6 o'clock position.





53. 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.

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





54. Remove the engine plug bolt.





55. 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 disassembly.

Install the special tool.





56. CAUTION:: The crankshaft must remain in the 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.

Using the special tool 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.





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

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









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

Remove and discard the CKP sensor.





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





60. 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.


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





62. Remove the RH timing chain guide.





63. Remove the timing chain.





64. Remove the 2 bolts and the LH timing chain guide.





65. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

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

Early build vehicles





66. Remove the oil pump chain tensioner and guide.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the shoulder bolt.
3. Remove the guide.





Late build vehicles

67. Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.

All vehicles

68. 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.

Remove the oil pump chain and sprockets.
1. Remove the bolt.
2. Remove the chain and sprockets.





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





70. 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.

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.





71. Remove the cylinder head.
^ Remove and discard the 10 cylinder head bolts.
^ Remove the cylinder head.
^ Remove and discard the cylinder head gasket.





72. Remove the cylinder head alignment dowels.





73. Remove the 13 bolts and the oil pan.





74. Remove the 6 bolts and the rear crankshaft seal.





75. Remove the 2 bolts, oil pump pickup tube and gasket.





76. Remove the 4 bolts and the oil pump.





77. Remove the 3 bolts and the intermediate shaft bearing bracket.