Part 2

Engine

Special Tool(s)














Material(s)






45. Remove the nut, 2 bolts and the A/C (Air Conditioning) compressor.





46. Remove the A/C (Air Conditioning) compressor mounting stud from the oil pan.





47. Remove the nut, bolt and the generator.





48. NOTE: If necessary, lubricate the LH (Left Hand) HO2S (Heated Oxygen Sensor) with penetrating and lock lubricant to assist in removal.
Remove the LH (Left Hand) HO2S (Heated Oxygen Sensor).





49. Remove the 3 bolts and the LH (Left Hand) exhaust heat shield.





50. Remove the 6 nuts and the LH (Left Hand) catalytic converter.

1. Discard the nuts and the gasket.






51. Clean and inspect the catalytic converter flange. REFER to Exhaust Manifold Cleaning and Inspection .

52. Remove and discard the 6 LH (Left Hand) exhaust manifold studs.





53. If equipped with FWD (Front Wheel Drive), remove the 4 nuts and the RH (Right Hand) catalytic converter. Discard the nuts and the gasket.






54. NOTE: Heat shield removed from graphic for clarity.
Remove the 6 nuts and the RH (Right Hand) exhaust manifold. Discard the nuts and exhaust manifold gaskets.





55. Clean and inspect the RH (Right Hand) exhaust manifold. REFER to Exhaust Manifold Cleaning and Inspection .

56. Remove and discard the 6 RH (Right Hand) exhaust manifold studs.





57. Remove the RH (Right Hand) cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.





58. Remove the LH (Left Hand) cylinder block drain plug. Allow coolant to drain from the cylinder block.





59. Remove the pin-type retainer and the cover.





60. Remove the 2 bolts and the 2 LH (Left Hand) CMP (Camshaft Position) sensors.





61. Remove the 2 bolts and the 2 LH (Left Hand) CMP (Camshaft Position) sensors.






62. Remove the 2 thermostat housing-to-lower intake manifold bolts.






63. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the 10 bolts and the lower intake manifold.

1. Remove and discard the intake manifold and thermostat housing gaskets.

2. Clean and inspect all sealing surfaces.






64. NOTE: Early built coolant tube shown, late build coolant tube similar.
Remove the coolant inlet tube and thermostat assembly.

1. Remove and discard the O-ring seal.






65. Disconnect and remove the CHT (Cylinder Head Temperature) sensor jumper harness.






66. Remove the bolt and the CKP (Crankshaft Position) sensor.





67. Remove the EOP (Engine Oil Pressure) switch.





68. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

If equipped, remove the 6 bolts and the oil cooler.

- Discard the oil cooler and gasket.






69. NOTE: Without oil cooler shown, with oil cooler similar.
Remove the 3 bolts and the oil filter adapter. Discard the gasket.





70. Remove the 3 bolts and the 3 LH (Left Hand)-coil-on-plugs.





71. NOTICE: While removing the valve cover do not apply excessive force to the VCT (Variable Camshaft Timing) oil control solenoid or damage may occur.

NOTICE: If the VCT (Variable Camshaft Timing) solenoid seal sticks to the VCT (Variable Camshaft Timing) oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.

NOTE: The plastic electrical connector on the VCT (Variable Camshaft Timing) oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.
Loosen the 4 bolts and 7 stud bolts. Remove the LH (Left Hand) valve cover. Discard the gasket.





72. Inspect the 2 VCT (Variable Camshaft Timing) solenoid seals. Remove any damaged seals.

1. Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) remove and discard the damaged seal(s).






73. Inspect the spark plug tube seals. Remove any damaged seals.

1. Using 303-1247/1 and 205-153 (T80T-4000-W) remove and discard the damaged seal(s).






74. Remove the 3 bolts and the 3 RH (Right Hand)-coil-on-plugs.





75. NOTICE: While removing the valve cover do not apply excessive force to the VCT (Variable Camshaft Timing) oil control solenoid or damage may occur.

NOTICE: If the VCT (Variable Camshaft Timing) solenoid seal sticks to the VCT (Variable Camshaft Timing) oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.

NOTE: The plastic electrical connector on the VCT (Variable Camshaft Timing) oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.
Loosen the 3 bolts and 8 stud bolts. Remove the RH (Right Hand) valve cover. Discard the gasket.





76. Inspect the 2 VCT (Variable Camshaft Timing) solenoid seals. Remove any damaged seals.

1. Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) remove and discard the damaged seal(s).






77. Inspect the spark plug tube seals. Remove any damaged seals.

1. Using 303-1247/1 and 205-153 (T80T-4000-W) remove and discard the damaged seal(s).






78. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.

79. Remove the 26 front cover bolts.





80. Using a suitable pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.





81. Rotate the crankshaft clockwise and align the timing marks on the intake VCT (Variable Camshaft Timing) assemblies as shown.





82. Remove the 3 bolts and the LH (Left Hand) valve train oil tube.





83. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position. Install the 303-1248 onto the flats of the LH (Left Hand) camshafts.





84. Remove the 3 bolts and the RH (Right Hand) valve train oil tube.





85. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position.
Install 303-1248 onto the flats of the RH (Right Hand) camshafts.






86. NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
Mark the timing chain link that aligns with the timing mark on the LH (Left Hand) intake VCT (Variable Camshaft Timing) assembly as shown.






87. Mark the timing chain link that aligns with the timing mark on the RH (Right Hand) intake VCT (Variable Camshaft Timing) assembly as shown.





88. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.





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 (Left Hand) primary timing chain guide.





92. NOTE: Removal of the VCT (Variable Camshaft Timing) oil control solenoid will aid in the removal of the primary timing chain.

NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Remove the bolt and the LH (Left Hand) intake VCT (Variable Camshaft Timing) oil control solenoid.





93. NOTE: Removal of the VCT (Variable Camshaft Timing) oil control solenoid will aid in the removal of the primary timing chain.

NOTE: A slight twisting motion will aid in the removal of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Remove the bolt and the RH (Right Hand) intake VCT (Variable Camshaft Timing) oil control solenoid.





94. Remove the primary timing chain.





95. NOTICE: Do not use power tools to remove the bolt or damage to the LH (Left Hand) primary timing chain guide may occur.

Remove the bolt and the upper LH (Left Hand) primary timing chain guide.





96. Remove the crankshaft timing chain sprocket.





97. NOTE: The 2 VCT (Variable Camshaft Timing) oil control solenoids are removed for clarity.

NOTE: The 303-1530 is inserted through a hole in the top of the mega cap.
Compress the LH (Left Hand) secondary timing chain tensioner and install the 303-1530 in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.





98. Remove and discard the 2 LH (Left Hand) VCT (Variable Camshaft Timing) assembly bolts.





99. Remove the 2 LH (Left Hand) VCT (Variable Camshaft Timing) assemblies and secondary timing chain. Remove the 303-1530.