Steps 41-80

Engine













WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

NOTICE: 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, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.

NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

41. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.





42. Disconnect the 2 turbocharger coolant hoses from the intake manifold.





43. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

Remove the 12 bolts and the intake manifold.

- Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.

- Clean and inspect all sealing surfaces.





44. Disconnect the RH VCT solenoid electrical connector and detach the 2 wiring harness retainers.





45. Disconnect the 3 RH ignition coil-on-plug electrical connectors.





46. Detach all the wiring harness retainers from the RH valve cover and stud bolts.

47. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.





48. Remove the bolt and the RH CMP sensor.





49. Remove the bolt and the radio capacitor from the RH cylinder head.





50. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector from the rear of the RH cylinder head.





51. Disconnect the LH CMP sensor electrical connector.





52. Remove the bolt and the LH CMP sensor.





53. Disconnect the turbocharger wastegate regulating valve hose from the LH turbocharger assembly.





54. Remove the 2 bolts and the LH turbocharger oil return tube from the turbocharger.
- Remove and discard the gasket.





55. Remove the LH turbocharger oil return tube from the oil pan.
- Discard the 2 O-ring seals.





56. Remove the LH oil supply tube secondary latch.





57. Using the Spring Lock Coupling Disconnect Tool, remove the LH oil supply tube from the quick connect fitting.
- Inspect and if necessary, replace the quick connect filtering.





58. Remove the 2 coolant tube banjo bolts and the LH turbocharger coolant tubes and sealing washers.
- Discard the sealing washers.





59. Remove the LH turbocharger oil supply tube banjo bolt.
- Discard the sealing washer.

- Discard the oil supply tube filter.





60. Remove the 2 bolts and the lower LH turbocharger-to-cylinder block bracket.





61. Remove the 2 bolts and the upper LH turbocharger bracket-to-cylinder block bracket.





62. Remove the 3 LH turbocharger-to-exhaust manifold bolts and turbocharger.
- Discard the gasket and bolts.





63. Remove the 8 LH exhaust manifold nuts (6 shown) and the exhaust manifold.
- Discard the exhaust manifold gasket and nuts.





64. Clean and inspect the LH exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.

65. Remove and discard the 8 LH exhaust manifold studs.





66. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

67. Remove the LH coolant tube bracket-to-cylinder head nut.





68. Remove the nut and the heat shield.





69. Remove the wiring harness retainer stud bolt.





70. Remove the wiring harness grommet.





71. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





72. Remove the bolt and the CKP sensor.





73. Remove the 5 bolts and the 2 upper RH exhaust manifold heat shields.





74. Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.





75. Remove the 2 bolts and the RH turbocharger oil return tube from the RH turbocharger.
- Remove and discard the gasket.





76. Remove the RH turbocharger oil return tube from the cylinder block.
- Discard the 2 O-ring seals.





77. Remove the RH oil supply tube secondary latch.





78. Using the Spring Lock Coupling Disconnect Tool, remove the RH oil supply tube from the quick connect fitting.
- Inspect and if necessary, replace the quick connect fitting.





79. Remove the 2 coolant tube banjo bolts and the RH turbocharger coolant tubes.
- Discard the sealing washers.





80. Remove the 3 bolts and the upper turbocharger-to-cylinder block bracket.