Part 2

Engine













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.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction 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.

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

45. Disconnect the RH VCT solenoid electrical connector and detach the 2 wiring harness retainers.





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





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

48. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.





49. Remove the bolt and the RH CMP sensor.





50. Remove the bolt and the radio capacitor from the RH cylinder head.





51. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector from the rear of the RH cylinder head.





52. Disconnect the LH CMP sensor electrical connector.





53. Remove the bolt and the LH CMP sensor.





54. Disconnect the turbocharger wastegate regulating valve hose from the LH turbocharger assembly.





55. Remove the 2 bolts and the LH turbocharger oil return tube from the turbocharger.
- Remove and discard the gasket.





56. Remove the LH turbocharger oil return tube from the oil pan.
- Discard the 2 O-ring seals.





57. Remove the LH oil supply tube secondary latch.





58. Using the Spring Lock Coupling Disconnect Tool, remove the LH oil supply tube from the quick connect fitting.
- Inspect and if necessary, replace the quick connect filtering.





59. Remove the 2 coolant tube banjo bolts and the LH turbocharger coolant tubes and sealing washers.
- Discard the sealing washers.





60. Remove the LH turbocharger oil supply tube banjo bolt.
- Discard the sealing washer.

- Discard the oil supply tube filter.





61. Remove the 2 bolts and the lower LH turbocharger-to-cylinder block bracket.





62. Remove the 2 bolts and the upper LH turbocharger bracket-to-cylinder block bracket.





63. Remove the 3 LH turbocharger-to-exhaust manifold bolts and turbocharger.
- Discard the gasket and bolts.





64. Remove the 8 LH exhaust manifold nuts (6 shown) and the exhaust manifold.
- Discard the exhaust manifold gasket and nuts.





65. Clean and inspect the LH exhaust manifold.

66. Remove and discard the 8 LH exhaust manifold studs.





67. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

68. Remove the LH coolant tube bracket-to-cylinder head nut.





69. Remove the nut and the heat shield.





70. Remove the wiring harness retainer stud bolt.





71. Remove the wiring harness grommet.





72. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





73. Remove the bolt and the CKP sensor.





74. Remove the 5 bolts and the 2 upper RH exhaust manifold heat shields.





75. Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.





76. Remove the 2 bolts and the RH turbocharger oil return tube from the RH turbocharger.
- Remove and discard the gasket.





77. Remove the RH turbocharger oil return tube from the cylinder block.
- Discard the 2 O-ring seals.





78. Remove the RH oil supply tube secondary latch.





79. Using the Spring Lock Coupling Disconnect Tool, remove the RH oil supply tube from the quick connect fitting.
- Inspect and if necessary, replace the quick connect fitting.





80. Remove the 2 coolant tube banjo bolts and the RH turbocharger coolant tubes.
- Discard the sealing washers.





81. Remove the 3 bolts and the upper turbocharger-to-cylinder block bracket.





82. Remove the 3 exhaust manifold-to-turbocharger bolts and the turbocharger assembly.
- Discard the gasket and bolts.





83. Remove the RH turbocharger oil supply tube banjo bolt.
- Discard the sealing washer.

- Discard the oil supply tube filter.





84. Remove the 8 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.





85. Clean and inspect the RH exhaust manifold.

86. Remove and discard the 8 RH exhaust manifold studs.





87. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

88. Remove the 2 bolts and the RH engine lifting eye.





89. Remove the RH coolant tube bracket-to-cylinder head bolt and the coolant tube assembly.





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