Part 2

Engine











Disassembly (Steps 35-68)

35. NOTE: LH shown, RH similar.

Remove the RH and the LH insulator bolts and brackets.





36. Remove the fuel supply tube bolt.





37. Remove the bolts and the fuel rail.





38. Remove the fuel injectors.
^ Remove and discard the O-ring seals.





39. NOTE: RH shown, LH similar.

Loosen the bolts and remove the valve covers.





40. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp and remove the thermostat housing.





41. Remove the bolt and the oil level indicator tube.





42. Remove the bolt and the KS.





43. Remove the nuts and the RH exhaust manifold and gasket.
^ Discard the nuts and the gasket.





44. Remove and discard the 6 RH exhaust manifold studs.
45. Remove the nuts and the LH exhaust manifold and gasket.
^ Discard the nuts and the gasket.





46. Remove and discard the 6 LH exhaust manifold studs.
47. Using the special tool to hold the crankshaft pulley, remove the bolt.





48. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.

Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley.
^ Discard the crankshaft pulley bolt.





49. Remove the bolts and the coolant pump pulley.





50. Remove the bolts and the coolant pump.





51. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the up position.





52. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the special tool, remove the camshaft roller followers.





53. Remove the RH hydraulic chain tensioner.





54. Install the special tools on the RH cylinder head and tighten the top 2 clamp bolts.
^ Tighten to 10 Nm (89 lb-in).





55. NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.

Remove the RH camshaft sprocket bolt.





56. Remove the bolt.





57. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





58. Remove the LH hydraulic chain tensioner.





59. Install the special tools on the LH cylinder head.





60. Remove the LH camshaft sprocket bolt.





61. Remove the bolt.





62. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.





63. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the bolts in the sequence shown and remove the cylinder heads.
^ Discard the gaskets and the bolts.





64. 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 cylinder head gasket.

Clean and inspect the cylinder head sealing surfaces.
65. Using the special tool, remove the crankshaft front oil seal.





66. Remove the 5 cylinder block cradle-to-engine front cover bolts.
67. Remove the bolts and the engine front cover.





68. Remove the bolts and the oil pan.