Disassemble

TOOL REQUIRED
- J 42069 Timing Belt Alignment Kit
- J 42065 Crank Hub Holding Tool
- J 42098 Crank Hub Torx Socket

1. Intake Plenum Removal





a. Remove the throttle body bolts.
b. Remove the throttle body from intake plenum.
c. Remove the gasket from intake plenum.





d. Remove the crankcase vent tube adapter cover.
e. Remove the crankcase vent tube adapter bolt.
f. Remove the crankcase vent tube adapter.





g. Remove the intake plenum bolt covers.
h. Remove the intake plenum bolts.
i. Remove the intake plenum.
j. Remove the intake seals.
2. Intake Manifold Removal





a. Remove the intake manifold bolts (1).
b. Remove the intake manifold (2).
c. Remove the seals (3).





d. Remove the intake manifold spacer bolts (1).
e. Remove the intake manifold spacer (2).
3. Water Crossover Removal





a. Remove the coolant intake pipe support bolt (3).
b. Remove the coolant intake pipe bolts (5).
c. Remove the coolant intake pipe (4).
d. Remove the coolant intake seal (6).





e. Remove the coolant bridge bolts (1).
f. Remove the coolant bridge upper seals (2).
g. Remove the coolant bridge (3).
h. Remove the coolant bridge lower seals (2).
4. Exhaust Manifold Removal





a. Remove the driver side exhaust manifold heat shield bolts.
b. Remove the driver side exhaust manifold heat shields.





c. Remove the AIR injection pipe bolts (1).
d. Reposition the AIR injection pipe clamp.
e. Remove the AIR injection pipe (2).
f. Remove the driver side exhaust manifold nuts.
g. Remove the driver side exhaust manifold.
h. Remove the driver side exhaust manifold gasket.





i. Remove the passenger side exhaust manifold heat shield bolts.
j. Remove the passenger side exhaust manifold heat shields.
k. Remove the AIR injection pipe bolts (1).
l. Reposition the AIR injection pipe clamp.
m. Remove the AIR injection pipe (2).
n. Remove the passenger side exhaust manifold nuts.
o. Remove the passenger side exhaust manifold.
p. Remove the passenger side exhaust manifold gasket.





5. Crankcase Vent Housing Removal
a. Remove the hoses from the chamber.
b. Remove the chamber bolts.
c. Remove the chamber.
d. Remove the chamber gasket.
6. Drive Belt Tensioner Removal
a. Loosen the following if removing the front timing belt cover:
^ Loosen the water pump pulley bolts.
^ Loosen the power steering pump pulley bolts





b. Use a wrench on the center bolt of the tensioner pulley (5) to rotate downward.
c. Remove the belt (7) from the tensioner.
d. Remove the belt from the accessory drive pulleys.





e. Remove the belt tensioner bolts.
f. Remove the tensioner from the engine.





7. Crankshaft Balancer Removal
a. Remove the harmonic balancer bolts.
b. Remove the harmonic balancer.





8. Timing Belt Cover Removal
a. Remove the water pump pulley bolts.
b. Remove the water pump pulley.
c. Remove the power steering pump pulley bolts.
d. Remove the power steering pump pulley.
e. Remove the front timing belt cover bolts.
f. Remove the front timing belt cover.
9. Timing Belt Removal





a. Rotate the crankshaft clockwise to 60° Before Top Dead Center (BTDC).





b. Install the Crankshaft Locking Tool to the crankshaft drive gear with the knurled bolt.
c. Use the Crank Hub Torx Socket to carefully turn the crankshaft in the engine rotational direction (clockwise) until the lever of the Crankshaft Locking Tool firmly contacts the water pump pulley flange.
d. Secure the moveable lever of the tool to the water pump pulley flange.

CAUTION: Ensure that the alignment of the crankshaft is not 180° off.

e. The alignment marks on the camshaft gears must align with the corresponding notches on the rear timing belt cover.





f. Install the Camshaft Locking Tools to the camshaft gears. If the Camshaft Locking Tools do not fit into the teeth of the camshaft gears, it may be necessary to loosen the relevant timing belt idler pulley and turn the eccentric until the Camshaft Locking Tools can be inserted.
g. Loosen the timing belt tensioner and idler pulleys, remove the timing belt.

CAUTION: Do not move the crankshaft while the timing belt is removed. Do not move the camshaft while the timing belt is removed. Do not remove the locking tools while the belt is removed.

10. Camshaft Cover Removal
a. Remove the oil filter tube from the driver side valve cover.





b. Remove the valve cover bolts (2).
c. Remove the valve cover (4). Important: Ensure that all eight sealing O-rings (3) are accounted for. O-rings may stick to the camshaft bearing caps. O-rings may fall into the oil return journals in the cylinder head.
d. Remove the valve cover seals.
11. Camshaft Drive Sprocket Removal

CAUTION: Some of the lobes on the camshafts may be under load from the lifters. Rotate the camshafts carefully until the camshafts are no longer under a load if applicable.

a. Install the Camshaft Locking Tool between camshaft gear 1 and 2 to hold the camshaft gears in place while removing the bolt.
b. Install the Camshaft Locking Tool between camshaft gear 3 and 4 to hold the camshaft gears in place while removing the bolt.





c. Remove the camshaft gear bolts.
d. Remove the camshaft gear washers.
e. Remove the camshaft gears.





12. Timing Belt Tensioner Pulley Removal
a. Remove the timing belt tensioner bracket bolts.
b. Remove the timing belt bracket tensioner.





13. Water Pump Removal
a. Remove the water pump bolts.
b. Remove the water pump and the seal.





14. Engine Rear Cover Removal
a. Remove the rear timing belt cover bolts.
b. Remove the rear timing belt cover.
15. Thermostat Removal





a. Remove the thermostat housing extension bolt (2).
b. Pull out the thermostat housing extension (3) from the thermostat housing to remove the thermostat housing extension.





c. Remove the thermostat housing bolts (1).
d. Remove the thermostat housing (2).
16. Oil Cooler Removal
a. Remove the oil cooler pipe fittings from the oil cooler.





b. Remove the oil cooler pipe seals from the oil cooler.





c. Remove the oil cooler pipe fittings from the engine block.
d. Remove the oil cooler pipes from the engine.





e. Remove the engine oil cooler inlet nuts.
f. Remove the engine oil cooler outlet nuts.
g. Remove the engine oil cooler cover bolts.
h. Remove the engine oil cooler cover.
i. Remove the engine oil cooler.
17. Oil Pan Removal





a. Remove the oil level sensor wire electrical connector C-clip (1) from the oil pan housing.
b. Remove the oil pan bolts.





c. Remove the oil pan from the oil pan housing.
d. Pull the oil level sensor electrical connection from the upper oil pan housing.
e. Remove the A/C compressor hose support strap bolt from the front of the oil pan housing.
f. Remove the oil pan housing bolts.
g. Remove the oil intake pipe bolts.
h. Remove the oil intake pipe.
18. Oil Pump Removal





a. Mount the Crank Hub Holding Tool to prevent movement of the crankshaft.
b. Use the Crank Hub Torx Socket to remove the crankshaft driver gear bolt.





c. Remove the crankshaft drive gear.





d. Remove the oil pump bolts.
e. Remove the oil pump.
f. Remove the front main oil seal and collar from the oil pump.
19. Camshaft Removal
a. Remove the camshaft bearing cap bolts.

CAUTION: Camshaft bearing caps are marked with an L or an R followed by a number. The caps marked with an L are on the passenger side cylinder head. The caps marked with an R are on the driver side cylinder head. DO NOT interchange the caps or damage to the cylinder head and/or camshaft may result.

b. Remove the camshaft bearing caps.
c. Remove the camshafts.
d. Remove the camshaft seals.
20. Cylinder Head Removal





a. Remove cylinder head bolts in the REVERSE order as shown in the supporting illustration.
b. Remove the cylinder heads.
c. Remove the cylinder head gaskets.
21. Crankshaft and Bearings Removal





a. Remove the crankshaft bearing bridge bolts (1).
b. Remove the main bearing cap bolts (2).
c. Remove the crankshaft bearing bridge.
d. Remove the first main bearing cap.
e. Remove the first main bearing cap lower insert.
f. Remove the second main bearing cap.
g. Remove the second main bearing cap lower insert.
h. Remove the third main bearing cap.
i. Remove the third main bearing cap lower insert.
j. Perform the following steps to remove the fourth main bearing cap.
^ Insert a bolt into the main bearing cap oil pan threaded hole.
^ Use a pry bar to pry the cap from the block.
^ Remove the fourth main bearing cap.
^ Remove the fourth main bearing cap lower insert.
k. Remove the crankshaft from the engine block.





l. Remove the crankshaft reluctor ring bolts.
m. Remove the crankshaft reluctor ring.
22. Piston, Connecting Rod, and Bearing Removal





a. Rotate the crankshaft until the rod bearing cap bolts are accessible.
b. Remove the rod bearing cap bolts.
c. Remove the rod bearing cap.
d. Remove the rod bearing cap insert.





CAUTION: Re-install the rod cap to the rod when the piston is removed from the engine block. The rod and the cap are not interchangeable. The mating surfaces must be protected from damage.

e. Use a block of wood or use a soft material to drive each piston out of the block.