Steps 81-124

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

81. Remove the 22 engine front cover bolts.





82. 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.





83. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.





84. 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.





85. 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.





86. Remove the 3 bolts and the RH VCT housing.





87. Remove the 3 bolts and the LH VCT housing.





88. Remove and discard the VCT housing seals.





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.





95. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





96. 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.





97. 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.





98. 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.





99. Remove the 2 bolts and the LH secondary timing chain tensioner.





100. 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.





101. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





102. 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.





103. Remove the Camshaft Holding Tool from the RH camshafts.





104. 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.





105. Remove the 2 bolts and the RH secondary timing chain tensioner.





106. Remove the 2 bolts and the RH primary timing chain guide.





107. 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.





108. 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.





109. NOTE: LH shown, RH similar.

Remove and discard the M6 bolt from each cylinder head.





110. 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.





111. 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.

112. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.

113. Remove the coolant tube.
- Remove and discard the O-ring seals.





114. Remove the 2 bolts and the KS.





115. Remove the 8 bolts and the coolant pump.





116. Remove the 16 oil pan bolts.





117. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan.
- Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
- Remove the oil pan.





Early build engines

118. Remove the 3 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.





Late build engines
119. Remove the 2 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.





All engines

120. Remove the 3 bolts and the oil pump.





121. Remove the 8 crankshaft rear seal retainer bolts.





122. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer.
- Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
- Remove the crankshaft rear seal retainer.





123. NOTICE: Only use a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.

- Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.

124. 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: Do not use wire brushes, power abrasive discs or 3M Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant.

Clean the sealing surfaces of the cylinder block in the following sequence.

1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep 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.

5. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.