Part 3

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

120. Loosen the 10 stud bolts and remove the LH valve cover.
- Discard the gasket.






121. Loosen the 11 stud bolts and remove the RH valve cover.
- Discard the gasket.






122. NOTE: VCT (Variable Camshaft Timing) solenoid seal removal shown, spark plug tube seal removal similar.

Inspect the VCT (Variable Camshaft Timing) solenoid seals and the spark plug tube seals. Install new seals if damaged.

- Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Remover and Handle, remove the seal(s).






123. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





124. Remove the 3 bolts and the accessory drive belt tensioner.





125. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.






126. Using the 3 Jaw Puller, remove the crankshaft pulley.





127. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





128. Remove the HO2S (Heated Oxygen Sensor) connector bracket stud bolt from the engine front cover.





129. NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.






130. Remove the 3 bolts and the engine mount bracket.





131. Remove the 22 engine front cover bolts.





132. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.





133. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.


134. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Do not use wire brushes, power abrasive discs or 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.


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





136. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

Install the Camshaft Holding Tool onto the flats of the LH camshafts.






137. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC (Top Dead Center) position.

Install the Camshaft Holding Tool onto the flats of the RH camshafts.






138. Remove the 3 bolts and the RH VCT (Variable Camshaft Timing) housing.





139. Remove the 3 bolts and the LH VCT (Variable Camshaft Timing) housing.





NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.

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





141. Mark the timing chain link that aligns with the timing mark on the LH intake VCT (Variable Camshaft Timing) assembly as shown.





142. 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.






143. Remove the 2 bolts and the primary timing chain tensioner.





144. Remove the primary timing chain tensioner arm.





145. Remove the 2 bolts and the lower LH primary timing chain guide.





146. Remove the primary timing chain.





LH camshafts

147. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





148. NOTE: The VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the LH VCT (Variable Camshaft Timing) assembly bolt and the LH exhaust camshaft sprocket bolt.

- Remove the LH VCT (Variable Camshaft Timing) assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.






149. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.






150. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Verify the LH camshafts are in the neutral position.






151. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the LH camshaft bearing caps.

- Remove the LH camshafts.






RH camshafts

152. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





153. NOTE: The VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Remove and discard the RH VCT (Variable Camshaft Timing) assembly bolt and the RH exhaust camshaft sprocket bolt.

- Remove the RH VCT (Variable Camshaft Timing) assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.






154. Remove the Camshaft Holding Tool from the RH camshafts.





155. NOTICE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Rotate the RH camshafts counterclockwise to the neutral position.






156. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Remove the bolts and the RH camshaft bearing caps.

- Remove the RH camshafts.