Steps 81-120
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.
81. Remove the 3 exhaust manifold-to-turbocharger bolts and the turbocharger assembly.
- Discard the gasket and bolts.
82. Remove the RH turbocharger oil supply tube banjo bolt.
- Discard the sealing washer.
- Discard the oil supply tube filter.
83. Remove the 8 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.
84. Clean and inspect the RH exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.
85. Remove and discard the 8 RH exhaust manifold studs.
86. 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.
87. Remove the 2 bolts and the RH engine lifting eye.
88. Remove the RH coolant tube bracket-to-cylinder head bolt and the coolant tube assembly.
89. Remove the pin-type retainer and the cover.
90. Detach the wiring harness retainer from the rear of the LH cylinder head.
91. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.
92. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.
93. Remove the nut for the high pressure fuel tube from the LH valve cover stud bolt and disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
94. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.
Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails and remove the high pressure fuel tube assembly.
95. Remove the 2 bolts and the fuel injection pump.
96. Remove the fuel injection pump mounting plate.
97. NOTE: Valve cover is removed for clarity.
Remove the fuel injection pump roller tappet.
- Inspect the fuel injection pump roller tappet. For additional information, refer to Fuel Charging and Controls Fuel Injection Pump Roller Tappet Inspection
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 following illustrations depict early build components, late build components similar.
98. NOTICE: It is very important to note the routing of the wiring harness on the fuel rails and index-mark the locations of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct wire harness routing and tie strap positioning for installation.
NOTE: Use compressed air to remove any dirt or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
Carefully cut and remove the fuel rail wire harness tie straps.
99. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the LH fuel rail.
100. Remove the 6 bolts and the RH fuel rail.
101. NOTE: RH shown, LH similar.
Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harnesses.
102. Remove and discard the 6 upper fuel injector O-ring seals.
103. Remove and discard the 6 fuel injector clips.
104. Using the Slide Hammer and the Fuel Injector Remover, remove the 6 fuel injectors.
105. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 RH ignition coils-on-plugs.
106. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 LH ignition coils-on-plugs.
107. Loosen the 10 stud bolts and remove the LH valve cover.
- Discard the gasket.
108. Loosen the 11 stud bolts and remove the RH valve cover.
- Discard the gasket.
109. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
110. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.
111. Using the 3 Jaw Puller, remove the crankshaft pulley.
112. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
113. Remove the stud bolt and Heated Oxygen Sensor (HO2S) connector bracket from the engine front cover.
114. NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.
115. Remove the 3 bolts and the engine mount bracket.
116. Remove the 22 engine front cover bolts.
117. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.
118. NOTE: Engine equipped with roller timing chain and stamped steel RH timing chain guide shown, other applications similar.
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown.
119. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.
120. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.
