Part 2

Engine

50. Inspect the fuel injection pump tappet. REFER to Fuel Injection Pump Tappet Inspection .

51. Remove the 3 nuts and the wiring harness support brackets.





52. Remove the 3 stud bolts and the fuel injection pump cover.

- Inspect and replace the gasket, if necessary.






53. Remove the 4 bolts and the coolant outlet.

- Inspect and replace the gasket, if necessary.






54. Remove the oil indicator.





55. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 4 bolts and the ignition coil-on-plug assemblies.





56. If equipped, remove the 4 engine appearance cover mounting stud.





57. Loosen the valve cover retainers and remove the valve cover

- Discard the valve cover gasket.






58. NOTE: The VCT (Variable Camshaft Timing) solenoid seals should only be replaced if they are damaged.
Remove any damaged VCT (Variable Camshaft Timing) solenoid seals using the 205-153 (T80T-4000-W) and 303-1247/1.





59. Turn the crankshaft until piston no.1 is 45 degrees before TDC (Top Dead Center) by using the guide holes on the engine front cover and the crankshaft pulley.





60. Remove the 2 bolts and the CKP (Crankshaft Position) sensor.





61. Remove the engine plug bolt.





62. NOTICE: Failure to position the No. 1 piston at TDC (Top Dead Center) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

NOTE: The 303-507 will contact the crankshaft and prevent it from turning past TDC (Top Dead Center). However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC (Top Dead Center) position during the crankshaft pulley removal and installation.

Install 303-507 and using the crankshaft pulley bolt, turn the crankshaft clockwise slowly until contact is made with 303-507.





63. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install the 303-1565 into the rear of both of the camshaft slots as shown.

1. Tighten the retainer.






64. NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced, remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

NOTE: The crankshaft must remain in the TDC (Top Dead Center) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with 303-D055 (D85L-6000-A) , and the crankshaft pulley bolt should be removed using an air impact wrench (1/2-in drive minimum).

Use 303-D055 (D85L-6000-A) to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

- Remove and discard the crankshaft pulley bolt and washer.

- Remove the crankshaft pulley.

- Remove the diamond washer and discard.






65. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using 303-409 (T92C-6700-CH) , remove the crankshaft front oil seal.





66. Remove the 22 bolts and the engine front cover.






67. NOTICE: Do not rely on the 303-1565 to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.





68. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.





69. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.

2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.

3. Insert a paper clip into the hole to retain the tensioner.






70. Remove the 2 bolts and the timing chain tensioner.





71. Remove the timing chain tensioner arm.





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





73. Remove the timing chain.





74. NOTE: The phaser and sprocket bolts must be discarded and new installed.

Remove the 2 bolts and the exhaust and intake camshaft phaser and sprockets.





75. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Remove the 303-1565 from the rear of both of the camshaft slots.





76. Remove the 2 bolts and the 2 VCT (Variable Camshaft Timing) oil control solenoids.





77. Remove the 3 bolts and the front camshaft bearing cap.





78. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

NOTICE: Note the position of the camshaft lobes on the No. 1 cylinder for installation reference.

NOTICE: Mark the location and orientation of each camshaft bearing cap.

Remove the camshafts from the engine.

1. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

2. Remove the camshaft bearing caps.

3. Remove the camshafts.






79. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
Remove the 16 valve tappets.






80. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
Inspect the valve tappets. REFER to Valve Tappet Inspection .

81. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

Remove the 10 bolts and the cylinder head.

- Discard the bolts.






82. Remove and discard the head gasket.






83. Remove the 2 cylinder head alignment dowels.





84. 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 and 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 surface of both the cylinder head 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 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.

85. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. REFER to Cylinder Head Distortion and REFER to Cylinder Block Distortion .

86. Remove the 12 bolts and the oil pan.






87. Remove the 2 bolts and the oil pump screen and pickup tube.

- Discard the gasket.






88. Remove the 6 bolts and the crankshaft rear seal with retainer plate.






89. Remove the oil pump drive chain tensioner.

1. Push the tensioner spring down and release the spring from under the shoulder bolt.

2. Remove the 2 shoulder bolts and the tensioner.

- Remove the chain from the oil pump sprocket.






90. Remove the crankshaft sprocket.

- Remove the diamond washer and discard.






91. Remove the bolt and oil pump sprocket.






92. Remove the 4 bolts and the oil pump.






93. Remove 303-507.





94. 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.

95. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
Remove the bolts and the connecting rod cap.





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

Using the 303-462 (T94P-6136-AH) , remove the piston/rod assembly from the engine block.

- Repeat until all the piston/rod assemblies are removed from the engine block.






97. Remove the 10 bolts in the sequence shown and the main bearing beam.





98. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the main bearings from the main bearing beam.





99. Remove the crankshaft from the engine block.





100. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.





101. NOTE: If the engine piston oil coolers are being reused, mark them in order for correct location during reassembly.

NOTE: The front bulkhead does not have an engine piston oil cooler.
Remove the 4 engine piston oil coolers.





102. Inspect the cylinder block, main bearing beam, pistons and connecting rods. REFER to Engine System - General Information.