Steps 61-108

Engine

















All vehicles

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, can cause engine failure.

NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.

NOTICE: If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.

NOTE: For additional information, refer to the exploded views under Engine Engine - Assembly in the Assembly.

61. Remove the 5 cylinder block cradle-to-engine front cover bolts.





62. Remove the 5 bolts, 5 stud bolts and the engine front cover.





63. Remove and discard the engine oil filter.





64. Remove the bolts and the oil pan.





65. Remove the bolt and the oil pump screen cover and tube.





66. NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.

Remove the 8 cylinder block cradle inner bolts. Remove and discard the 2 washer seals.





67. Remove the 2 cylinder block cradle Torx bolts.





68. Remove the 15 bolts and the 2 nuts.
- Remove the cylinder block cradle.





69. Remove the 2 bolts, the oil pump pickup tube and the oil pump intermediate shaft.





70. Remove the oil filter adapter.





71. Remove the 2 bolts and the jackshaft chain tensioner.





72. Remove the 2 bolts and the jackshaft chain guide.





73. Remove the jackshaft rear plug.





74. Install the Rear Jack Shaft Socket on the rear of the jackshaft.





75. Using the Rear Jack Shaft Socket to hold the jackshaft, loosen the jackshaft sprocket bolt.





76. Using the Rear Jack Shaft Socket to hold the jackshaft, loosen the rear jackshaft sprocket bolt.





77. NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12 external Torx socket, in order to remove the bolt if the bolt does not turn out easily at this time.

Remove the jackshaft sprocket bolt.





78. Remove the jackshaft and crankshaft sprockets and the chain.
- Remove the crankshaft key.





79. Remove the bolt and the LH camshaft drive cassette.





80. Remove the RH camshaft drive cassette bolt and spacer.





81. NOTE: It may be necessary to hold the oil pump intermediate shaft, using an E-12 external Torx socket, in order to remove the bolt if the bolt does not turn out easily at this time.

Remove the rear jackshaft sprocket bolt and remove the RH camshaft drive cassette.





82. Remove the bolt, the hold down and the oil pump drive.





83. Remove the 2 bolts and the jackshaft thrust plate.





84. Remove the jackshaft.





85. Remove the jackshaft spacer.





86. Using the Crankshaft Holding Tool, loosen the front sprocket retaining bolt.





87. Remove the bolts and the chain tensioner.





88. Remove the chain guide.





89. Remove the bolt.





90. Remove the jackshaft sprocket and chain.





91. Remove the LH cassette bolt.





92. Remove the LH cassette.





93. Remove the jackshaft thrust plate.





94. Remove the jackshaft.





Vehicles equipped with a balance shaft

95. Remove the balance shaft tensioner.

1. Install a pin in the balance shaft tensioner.

2. Remove the 2 bolts.

3. Remove the balance shaft tensioner.





96. Remove the 2 bolts and the balance shaft chain guide.

97. NOTE: DO NOT remove the balance shaft sprocket bolt.

Remove the balance shaft chain and crankshaft sprocket.





98. Remove the balance shaft.

1. Remove the 2 bolts.

2. Remove the balance shaft.





All vehicles

99. 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 the manufacturer's instructions.

100. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.

Remove the connecting rod caps.

1. Remove the connecting rod nuts.

2. Remove the connecting rod caps.





101. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.





102. Remove the connecting rod bearings.





103. Remove the piston rings.





104. Clean and inspect the pistons.

105. NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: Number (or mark) the crankshaft bearing caps before removing them.

Remove the bolts and the crankshaft main bearing caps.





106. Remove the crankshaft rear oil seal from the crankshaft.





107. Remove the crankshaft.





108. Remove the crankshaft main bearings and the thrust bearing.