Disassembly And Assembly: Engine: Disassembly
WARNING: This page is about a different variant/trim than selected.
NOTE:
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTE:
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.
- 1.
Install the 303-103 T74P-6375-A and remove the 6 bolts and the flexplate.- Discard the bolts.
- Mount the engine on a suitable Engine Stand.
NOTE:
Do not reuse the flexplate bolts.
- 5.
Remove the engine appearance cover mounting stud and position the EVAP canister purge valve aside.
- 7.
Remove the 2 turbocharger coolant tube banjo bolts and discard the gaskets.- Loosen the 2 clamps and remove the turbocharger coolant tube.
- 10.
Remove the 2 banjo bolts and the turbocharger oil supply tube.- Discard the gaskets.
NOTE:
Do not reuse the turbocharger oil supply tube gaskets, new parts must be installed.
- 12.
Remove the 4 bolts and the turbocharger oil return tube.- Discard the turbocharger oil return tube and gaskets.
NOTE:
Do not reuse the turbocharger oil return tube or gaskets, new parts must be installed.
- 16.
Slide the insulator up and disconnect the CHT sensor electrical connector.- Detach the wiring harness retainer.
- Disconnect the ECT sensor electrical connector.
- Remove the bolt and the ground wire.
- 22.
Remove the 3 bolts and the coolant pump pulley.- Remove the 3 bolts and the accessory drive belt tensioner.
- Remove the 2 bolts and the generator.
- 23.
Remove the 3 bolts and the coolant pump.- Remove the bolt, the nut and the A/C compressor bracket assembly.
- 24.
Disconnect the EVAP tube quick connect coupling. REFER to Fuel System General Information .- Detach the heater hose retainer from the intake manifold.
- Loosen the clamp and remove the heater hose.
- Loosen the clamp and remove the CAC outlet tube.
- 25.
Disconnect the EOP switch electrical connector.- Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
- 26.
Disconnect the EVAP tube quick connect coupling. REFER to Fuel System General Information .- Detach the 2 EVAP tube retainers.
- 27.
Disconnect the EVAP canister purge valve electrical connector.- Remove the EVAP canister purge valve and tube assembly.
- 28.
Disconnect the fuel supply tube from the fuel injection pump. REFER to Fuel System General Information .- Detach the 2 fuel tube retainers from the intake manifold.
- Remove the bolt and the fuel jumper tube.
- 29.
Disconnect the 2 brake vacuum tube quick connect couplings. REFER to Fuel System General Information .- Depress the quick release locking ring and pull the brake vacuum tube out of the intake manifold quick connect fitting.
- 31.
Disconnect the 2 vacuum hoses from the intake manifold.- Detach the vacuum tube retainer from the intake manifold.
- 33.
Disconnect the TB electrical connector and detach the wiring harness retainer from the TB.- Detach the 2 KS wiring harness retainers from the intake manifold.
- Disconnect the PCV hose and remove the intake manifold.
- 34.
Disconnect the 2 KS electrical connectors.- Remove the 2 bolts and the 2 KS.
- Detach the 2 wiring harness retainers.
- 35.
Remove the 8 bolts and the crankcase vent oil separator.- Loosen the 2 clamps and remove the coolant bypass hose.
- 38.
Disconnect the fuel injection pump electrical connector.- Remove the fuel injection pump insulator.
- 39.
Loosen the 2 high pressure fuel tube flare nuts.- Remove the 2 bolts and the high pressure fuel tube.
- Discard the high pressure fuel tube.
NOTE:
To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.
- 40.
Remove the 5 bolts and the fuel rail.- Remove the 2 bolts and the high pressure fuel tube.
- Discard the bolts.
NOTE:
When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder head and require the use of a 310-206 to extract.
NOTE:
Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.
- 42.
Using the 307-005 T59L-100-B and the 310-206, remove the fuel injectors that remained in the cylinder head.
- 44.
Discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.
- 45.
Pull the lower Teflon ® seal away from the injector with narrow tip pliers.
NOTE:
Be very careful when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.
NOTE:
Do not attempt to cut the lower Teflon ® seal without first pulling it away from the fuel injector or damage to the injector may occur.
- 50.
Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.- Remove the fuel injection pump.
- 52.
Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
- 54.
Disconnect the 9 wiring harness electrical connectors.- Detach the 7 retainers and remove the wiring harness from the engine.
- 56.
Remove the oil level indicator.- Remove the 4 coil-on-plugs.
- Remove the nut, bolt and CAC intermediate tube mounting bracket.
- 58.
Remove any damaged VCT solenoid seals using the 303-1247/1 and 205-153 T80T-4000-W.- Discard the valve cover gasket.
NOTE:
The VCT solenoid seals should only be replaced if they are damaged.
- 60.
Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.
- 61.
Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
NOTE:
Turn the engine in the normal direction of rotation only.
- 64.
Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507.
NOTE:
The engine front cover is shown removed in graphic for clarity.
NOTE:
The 303-507 will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
- 65.
Install the 303-1565 into the rear of both of the camshaft slots as shown.- Tighten the retainer.
NOTE:
The camshaft timing slots are offset. If the 303-1565 cannot be installed, remove the 303-507 and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.
NOTE:
The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
- 66.
Use strap wrench 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.
NOTE:
The crankshaft sprocket diamond washer may come off with the crankshaft pulley.
NOTE:
The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
- 67.
If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
NOTE:
The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.
- 68.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
NOTE:
Use care not to damage the engine front cover or the crankshaft when removing the seal.
- 70.
Remove the 21 bolts, the stud bolt and the engine front cover.- Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE:
Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
- 71.
Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.
NOTE:
Do not rely on the 303-1565 to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
- 72.
Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.
NOTE:
Do not rely on the 303-1565 to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
- 73.
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.
- 1.
- 75.
Remove the timing chain tensioner arm.- Remove the 2 bolts and the timing chain guide.
- Remove the timing chain.
- 77.
If equipped, discard the washers.
NOTE:
Washers are not required for installation of the VCT units.
- 80.
Remove the camshafts from the engine.- Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
- Remove the camshaft bearing caps.
- Remove the camshafts.
NOTE:
Inspect the camshaft bores for any scratches that can be felt by hand.
NOTE:
Note the position of the camshaft lobes on the No. 1 cylinder for installation reference.
NOTE:
Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
- 81.
Remove the 16 valve tappets.- Inspect the valve tappets. REFER to Engine System General Information .
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.
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.
- 83.
Clean the cylinder head-to-cylinder block mating surfaces 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 remaining 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.
- 1.
NOTE:
If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
NOTE:
Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
NOTE:
Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE:
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.
- 84.
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 Engine System General Information - Cylinder Head Distortion and REFER to Engine System General Information - Cylinder Block Distortion. .
NOTE:
Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
- 90.
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, the tensioner and the oil pump chain.
- 1.
- 92.
Remove the diamond washer.
NOTE:
The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.
- 95.
Make sure the 303-507 is still installed and the engine is still at TDC.- If necessary, rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the 303-507.
- 96.
Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC.
- 97.
Remove the 4 bolts and the balance shaft assembly.
NOTE:
Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
- 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 manufacturer's instructions.
- 100.
Remove the 8 bolts and the 4 connecting rod caps.
NOTE:
Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
- 101.
Remove the 4 piston and rod assemblies from the engine block.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
- 103.
Remove the main bearings from the main bearing beam.
NOTE:
If the main bearings are being reused, mark them in order for correct orientation and reassembly.
- 105.
Remove the main bearings from the cylinder block.
NOTE:
If the main bearings are being reused, mark them in order for correct orientation and reassembly. The center bulkhead has the thrust bearing.
