Part 2 of 2

Item 86: RH Exhaust Manifold Removal Note





1. Remove the EGR tube
^ Remove the nuts
^ Remove the EGR tube.
^ Remove and discard the EGR tube gasket

Items 89 and 90: Engine Front Cover Removal Note





1. Remove the engine front cover
^ Remove the bolts in the sequence shown.
^ Remove the engine front cover





2. CAUTION: 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the sealing surfaces.

Items 97-115,112-122,124: Timing Drive Components Removal Note





1. Remove the Crankshaft Position (CKP) sensor.





2. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.

Install the special tool.
^ Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
^ Install the special tool.





3. Make sure the flats of the camshaft are facing upward. If not, repeat Step 1.





4. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the RH cylinder head.





5. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the exhaust camshaft sprocket bolt.





6. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.

Remove and discard the Variable Camshaft Timing (VCT) unit bolt.





7. Remove the RH timing chain tensioner.
1 Push the lever down and install a drill rod to lock the piston.
2 Remove the bolts and the tensioner.





8. Remove the tensioner arm.





9. Remove the tinning chain guide.





10. Remove the RH primary timing chain.





11. Remove the special tool from the RH head.





12. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the LH head.





13. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.

Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.





14. Remove the LH timing chain tensioner.
1 Push the lever down and install a drill rod to lock the piston.
2 Remove the bolts and the tensioner.





15. Remove the tensioner arm.





16. Remove the timing chain guide.





17. Remove the LH primary timing chain.





18. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.





19. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly





20. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.





21. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly





22. Remove the special tool from the L,H head.

Items 126-141: RH and LH Camshaft Removal Note

1. CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.

CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.

CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.

Record the camshaft component locations prior to removal.

Items 142-147: RH and LH Cylinder Head Removal Note





1. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: RH cylinder head shown, LH cylinder similar.

Remove and discard the bolts.





2. NOTE: RH cylinder head shown, LH cylinder similar.

Remove and discard the head bolts in the sequence shown.





3. NOTE: RH cylinder head shown, LH cylinder similar.

Remove and discard the head gasket(s).

4. CAUTION: 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

CAUTION: 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 head and the cylinder block.
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 it 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.

5. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper third 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).