Part 2

Camshaft














Removal

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.

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.

All camshafts

83. Disconnect the brake vacuum tube from the intake manifold.






84. Disconnect the 2 quick connect couplings and remove the PCV tube.





85. Disconnect the LH turbocharger bypass valve electrical connector.






86. NOTE: Index-mark the hoses for installation.
Disconnect the turbocharger wastegate regulating valve hoses from the RH CAC (Charge Air Cooler) tube and turbocharger wastegate regulating valve.






87. Loosen the clamp and remove the LH turbocharger intake tube from the LH turbocharger.





88. Disconnect the RH turbocharger bypass valve electrical connector.





89. Loosen the clamp and remove the RH CAC (Charge Air Cooler) tube from the RH turbocharger.





90. Loosen the clamp and remove the RH turbocharger intake pipe from the RH turbocharger.





91. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the nut from the RH valve cover stud bolt for the RH turbocharger intake tube.






92. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the RH CAC (Charge Air Cooler) tube nut from the intake manifold and remove the RH CAC (Charge Air Cooler) tube and turbocharger intake tube as an assembly.





93. Remove the noise insulator shield for the fuel injection pump and disconnect the electrical connector.





94. Disconnect the Throttle Position (TP) sensor and electronic TB (Throttle Body) electrical connectors.





95. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.





96. Disconnect the Engine Oil Pressure (EOP) electrical connector.
- Detach the wiring harness retainer from the block.






97. Disconnect the 3 LH ignition coil-on-plug electrical connectors.





98. Remove the lower radiator hose from the thermostat housing.





99. Remove the engine cover mounting stud from the LH valve cover stud bolt.





100. Detach all the wiring harness retainers from the LH valve cover and stud bolts.

101. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.





102. Remove the oil level indicator.





103. Detach and disconnect the 2 fuel injector wiring harness electrical connectors.





104. Disconnect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.





105. Disconnect the turbocharger wastegate regulating valve electrical connector.





106. Detach the 2 wire harness-to-intake manifold retainers.





107. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.





108. Disconnect the 2 turbocharger coolant hoses from the intake manifold.





109. 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.

NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.
Remove the 12 bolts and the intake manifold.
- Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.

- Clean and inspect all sealing surfaces.






110. Disconnect the RH VCT (Variable Camshaft Timing) solenoid electrical connector and detach the 2 wiring harness retainers.





111. Disconnect the 3 RH ignition coil-on-plug electrical connectors.





112. Detach all the wiring harness retainers from the RH valve cover and stud bolts.

113. Remove the nut for the high pressure fuel tube from the LH valve cover stud bolt.





114. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.
Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails and remove the high pressure fuel tube assembly.






115. Remove the 2 bolts and the fuel injection pump.





116. Remove the fuel injection pump mounting plate.





117. NOTE: Valve cover is removed for clarity.
Remove the fuel injection pump roller tappet.

- Inspect the fuel injection pump roller tappet.






118. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 LH ignition coil-on-plugs.






119. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the 3 bolts and the 3 RH ignition coil-on-plugs.