Part 3
Engine continued80. Remove the 2 nuts and the wiring harness retaining bracket.
81. Remove the 11 stud bolts and the LH valve cover.
^ Discard the gasket.
82. Remove the bolt, the 10 stud bolts and the RH valve cover.
^ Discard the gasket.
83. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
^ Using the special tools, remove the seal(s).
84. Remove the crankshaft bolt and washer.
^ Discard the bolt.
85. Using the special tool, remove the crankshaft pulley.
86. Using the special tool, remove and discard the crankshaft front seal.
87. Remove the 2 engine mount studs.
88. Remove the 3 bolts and the engine mount bracket.
89. Remove the 22 engine front cover bolts.
90. Install 4 of the engine front cover bolts (finger tight) into the 4 threaded holes in the engine front cover.
1 Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
2 Remove the engine front cover.
91. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
92. NOTE: The special tool will hold the camshafts in the top dead center position.
Install the special tool onto the flats of the LH camshafts.
93. NOTE: The special tool will hold the camshafts in the top dead center position.
Install the special tool onto the flats of the RH camshafts.
94. Remove the 3 bolts and the RH VCT housing.
95. Remove the 3 bolts and the LH VCT housing.
96. Remove and discard the VCT housing seals.
97. Remove the 2 bolts and the primary timing chain tensioner.
98. Remove the primary timing chain tensioner arm.
99. Remove the 2 bolts and the lower LH primary timing chain guide.
100. Remove the primary timing chain.
101. Remove the crankshaft timing chain sprocket.
102. Remove the 2 bolts and the upper LH primary timing chain guide.
103. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
104. 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 LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
105. NOTE: When the special tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Remove the special tool from the LH camshafts.
106. CAUTION: The camshafts must remain in the neutral position during removal.
Verify the LH camshafts are in the neutral position.
107. Remove the 2 bolts and the LH secondary timing chain tensioner.
108. CAUTION: 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.
109. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
110. 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.
111. Remove the special tool from the RH camshafts.
112. CAUTION: The camshafts must remain in the neutral position during removal.
Rotate the RH camshafts counterclockwise to the neutral position.
113. Remove the 2 bolts and the RH secondary timing chain tensioner.
114. Remove the 2 bolts and the RH primary timing chain guide.
115. CAUTION: 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.
116. CAUTION: 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.
117. NOTE: LH shown, RH similar.
Remove and discard the M6 bolt from each cylinder head.
118. 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 must be 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: LH shown, RH similar.
Remove and discard the 8 bolts from each cylinder head.
^ Remove the cylinder heads.
^ Discard the cylinder head gaskets.
119. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the gasket.
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 heads 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 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.
120. Support the cylinder heads on a bench with the head gasket side up.
121. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.
Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder heads must not have depressions deeper than 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).
122. Remove the coolant tube.
^ Remove and discard the O-ring seals.
123. Remove the 2 bolts and the knock sensor (KS).
124. Remove the 8 bolts and the coolant pump.
125. Remove the 16 oil pan bolts.
126. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan.
1 Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
2 Remove the oil pan.
127. Remove the 3 bolts and the oil pump screen and pickup tube.
^ Discard the O-ring seal.
128. Remove the 3 bolts and the oil pump.
129. Remove the 8 crankshaft rear seal retainer bolts.
130. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer.
1 Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
2 Remove the crankshaft rear seal retainer.
131. CAUTION: Place clean, lint free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
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 that make leak paths. Use a plastic scraping tool to remove all traces of the gasket.
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.
Clean all engine sealing surfaces, including the engine front cover, oil pan, crankshaft rear seal retainer and 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 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. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.