Part 2
Engine
NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.
NOTICE: If the fuel rail is used as a leverage device, it may be damaged. Care must be taken when working around the fuel rail.
NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or foreign material. Remove all caps, tape and other protective materials prior to installation.
NOTE: For additional information, refer to the exploded views under Engine Engine - Assembly in the Assembly.
51. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the RH cylinder head and tighten the top 2 clamp bolts.
- Tighten to 10 Nm (89 lb-in).
52. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
Remove the RH camshaft sprocket bolt.
53. Remove the bolt.
54. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
55. Remove the LH hydraulic chain tensioner.
56. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the LH cylinder head.
57. Remove the LH camshaft sprocket bolt.
58. Remove the bolt.
59. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
60. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Remove the 10 bolts in the sequence shown and remove the cylinder heads.
- Discard the gaskets and the bolts.
61. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
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 head gaskets.
NOTE: Observe all warnings and 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 surface of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone 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 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.
62. 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.
63. Remove the 2 bolts and the CKP sensor.
64. Using the Strap Wrench to hold the crankshaft pulley, remove the bolt.
65. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.
Install the crankshaft pulley bolt 2 to 3 turns. Using the 2 Crankshaft Vibration Damper Removers and the two 8-mm bolts, remove the crankshaft pulley.
- Discard the crankshaft pulley bolt.
66. Remove the 4 bolts and the coolant pump pulley.
67. Remove the 13 bolts and the coolant pump.
68. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
69. Remove the 5 cylinder block cradle-to-engine front cover bolts.
70. Remove the 5 bolts, 5 stud bolts and the engine front cover.
71. Remove the 10 bolts and the oil pan.
72. Remove the bolt and the oil pump screen cover and tube.
73. NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.
Remove the 8 cylinder block cradle inner bolts. Remove and discard the 2 washer seals.
74. Remove the 2 cylinder block cradle Torx bolts.
75. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.
76. Remove the 2 bolts, the oil pump pickup tube, the oil pump and the oil pump intermediate shaft.
77. Remove the bolt and the oil filter adapter.
78. Remove the 2 bolts and the jackshaft chain tensioner.
79. Remove the 2 bolts and the jackshaft chain guide.
80. Remove the jackshaft rear plug.
81. Install the Rear Jack Shaft Socket on the rear of the jackshaft.
82. Using the Rear Jack Shaft Socket to hold the jackshaft, loosen the jackshaft sprocket bolt.
83. Using the Rear Jack Shaft Socket to hold the jackshaft, loosen the rear jackshaft sprocket bolt.
84. NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12 external Torx socket, in order to remove the bolt if the bolt does not turn out easily at this time.
Remove the jackshaft sprocket bolt.
85. Remove the jackshaft and crankshaft sprockets and the chain.
- Remove the crankshaft key.
86. Remove the bolt and the LH camshaft drive cassette.
87. Remove the RH camshaft drive cassette bolt and spacer.
88. NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12 external Torx socket, in order to remove the bolt if the bolt does not turn out easily at this time.
Remove the rear jackshaft sprocket bolt and remove the RH camshaft drive cassette.
89. Remove the bolt, the hold down and the oil pump drive.
90. Remove the 2 bolts and the jackshaft thrust plate.
91. Remove the jackshaft.
92. Remove the jackshaft spacer.
93. Remove the balance shaft tensioner.
1. Install a pin in the balance shaft tensioner.
2. Remove the 2 bolts.
3. Remove the balance shaft tensioner.
94. Remove the 2 bolts and the balance shaft chain guide.
95. NOTE: DO NOT remove the balance shaft sprocket bolt.
Remove the balance shaft chain and crankshaft sprocket.
96. Remove the balance shaft.
1. Remove the 2 bolts.
2. Remove the balance shaft.
97. 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 the manufacturer's instructions.
98. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.
Remove the connecting rod caps.
1. Remove the 2 connecting rod nuts from each connecting rod.
2. Remove the connecting rod cap.
99. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
100. Remove the connecting rod bearings.
101. Remove the piston rings.
102. Clean and inspect the pistons. For additional information, refer to Engine.
103. NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
Remove the 8 bolts.
104. NOTE: Number (or mark) the crankshaft bearing caps before removing them.
Remove the 4 crankshaft main bearing caps.
105. Remove the crankshaft rear oil seal from the crankshaft.
106. Remove the crankshaft.
107. Remove the crankshaft main bearings and the thrust bearing.
