Part 5

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: 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.

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





137. 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.






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





139. NOTE: The VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) assembly bolt and the RH exhaust camshaft sprocket bolt.

- Remove the RH VCT (Variable Camshaft Timing) assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.






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





141. 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.






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





143. Remove the bolt and the RH timing chain guide.





144. 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.






145. 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.






146. NOTE: LH shown, RH similar.
Remove and discard the M6 bolt from each cylinder head.






147. 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 torque-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.






148. 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.


149. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to Engine.

150. Remove the coolant inlet tube.
- Remove and discard the O-ring seal.






151. Remove the 2 bolts and the KS (Knock Sensor).





152. Remove the 8 bolts and the coolant pump.





153. Remove the 16 oil pan bolts.





154. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.





155. Remove the 2 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.






156. Remove the 3 bolts and the oil pump.





157. Remove the 8 crankshaft rear seal retainer bolts.





158. 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.






159. NOTICE: Only use a 3M(TM) 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(TM) 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.


160. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.

161. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
Remove the bolts in the sequence shown.

- Remove the main bearing cap support brace.

- Discard the bolts.






162. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.

NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and cap.






163. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Remove the piston/rod assembly from the engine block.






164. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.

165. NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown.
- Discard the bolts.






166. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the 4 main bearing caps.






167. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.






168. NOTE: Inside shown, outside similar.
Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.






169. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the 4 crankshaft main bearings from the cylinder block.






170. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the 4 crankshaft main bearings from the main bearing caps.






171. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods.

172. 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(TM) 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.