Steps 81-120
Engine
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.
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: For additional information, refer to the exploded view under the Assembly procedure.
81. 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.
82. 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.
83. 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.
84. Remove the 3 bolts and the RH VCT housing.
85. Remove the 3 bolts and the LH VCT housing.
Engines equipped with a roller timing chain
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
86. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
87. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
88. Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown.
89. Remove the 2 bolts and the primary timing chain tensioner.
90. Remove the primary timing chain tensioner arm.
91. Remove the 2 bolts and the lower LH primary timing chain guide.
92. Remove the primary timing chain.
93. Remove the crankshaft timing chain sprocket.
94. Remove the 2 bolts and the upper LH primary timing chain guide.
Engines equipped with an inverted tooth timing chain
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
95. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
96. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
97. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.
98. Remove the 2 bolts and the primary timing chain tensioner.
99. Remove the primary timing chain tensioner arm.
100. Remove the 2 bolts and the lower LH primary timing chain guide.
101. Remove the primary timing chain.
102. Remove the crankshaft timing chain sprocket.
103. Remove the bolt and the upper LH primary timing chain guide.
All engines
104. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
105. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
- Remove the VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
106. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.
107. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Verify the LH camshafts are in the neutral position.
108. Remove the 2 bolts and the LH secondary timing chain tensioner.
109. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the LH camshaft bearing caps.
- Remove the LH camshafts.
110. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
111. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
- Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
112. Remove the Camshaft Holding Tool from the RH camshafts.
113. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Rotate the RH camshafts counterclockwise to the neutral position.
114. Remove the 2 bolts and the RH secondary timing chain tensioner.
115. 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.
Remove the bolt(s) and the RH timing chain guide.
1. Roller timing chain stamped steel RH guide.
2. Roller timing chain composite RH guide.
3. Inverted tooth timing chain RH guide.
116. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the RH camshaft bearing caps.
- Remove the RH camshafts.
117. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
NOTE: LH shown, RH similar.
Remove the valve tappets from the cylinder heads.
118. NOTE: LH shown, RH similar.
Remove and discard the M6 bolt from each cylinder head.
119. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
NOTICE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
NOTE: LH shown, RH similar.
Remove and discard the 8 bolts from each cylinder head.
- Remove the cylinder heads.
- Discard the cylinder head gaskets.
120. 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 gasket.
NOTE: Observe all warnings or 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 surfaces of both the cylinder heads and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or 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 remaining 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.