Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Remove the oil fill cap.
- Drain the engine oil. Engine Oil and Oil Filter Replacement
- Drain the cooling system. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill)
- Disconnect the battery. Battery Negative Cable Disconnection and Connection
Lift up on the front of the intake manifold cover (1).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Electrical Connector (1) - Disconnect [3x]
- Retainer (2) @ Upper Intake Manifold Bracket (3) - Unclip
- Wiring Harness (4) - Reposition
Upper Intake Manifold Cover Bolt (1) @ Upper Intake Manifold Bracket (2) - Remove [2x]
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Upper Intake Manifold Bracket (2) - Remove
Disconnect the evaporative emission canister purge tube quick disconnects (1). Plastic Collar Quick Connect Fitting Service
- Disconnect the evaporative emission canister purge tube (2) from the retainer (3).
Disconnect the electrical connector at the evaporative emission canister purge pump (2).
- Evaporative Emission Pipe (1) @ Evaporative Emission Canister Purge Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Front Pipe (1) - Reposition away
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Radiator Surge Tank Inlet Hose Clamp (1) @ Radiator Surge Tank Outlet Pipe (3) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Radiator Surge Tank Outlet Pipe (3) - Remove [2x]
Radiator Surge Tank Inlet Hose Clip (1) @ Positive Crankcase Ventilation Hose - Remove
- Radiator Surge Tank Inlet Hose Clip (3) @ Fuel Pump Cover - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Engine Wiring Harness - Remove
Radiator Surge Tank Inlet Hose Clip (1) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Outlet Pipe (3) - Remove
Reposition wiring harness as necessary.
- Fuel Pump Shield Bolt (1) - Remove [3x]
- Fuel Pump Cover (2) - Remove
Fuel Feed Pipe (1) @ Fuel Pump - Disconnect - Metal Collar Quick Connect Fitting Service
Disconnect the fuel pump electrical connector.
- Fuel Pump Insulator (1) - Remove
Reposition wiring harness as necessary.
- Fuel Injection Fuel Feed Pipe Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- CAUTION:
Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
Fuel Pump Bolt (4) - Remove [2x]
- Fuel Pump (1) - Remove
- Fuel Pump Seal (3) - Remove and DISCARD
- Valve Lifter Follower (2) - Remove
Positive Crankcase Ventilation Tube (1) - Disconnect [2x] - Plastic Collar Quick Connect Fitting Service
- Retainer (2) - Unclip
Wiring Harness Retainer (1) @ Air Cleaner Assembly - Remove [4x]
- Electrical Connector (4) - Disconnect [2x]
Air Cleaner Bolt (1) - Remove
- Air Cleaner Outlet Duct Clamp (2) - Loosen
Remove the air cleaner (1) and air cleaner outlet duct (2) as an assembly.
Disconnect the electrical connector.
- Positive Crankcase Ventilation Hose Connector Bolt (1) - Remove [2x]
- Retainer (2) - Unclip
- Positive Crankcase Ventilation Hose (3) - Remove
- Positive Crankcase Ventilation Hose Fitting Seal (4) - Remove and DISCARD [2x]
Retainer Spring (1) - Release
- Charge Air Cooler Inlet Air Tube (2) @ Compressor Air Intake Turbocharger (3) - Remove
- Disconnect and reposition heated oxygen sensor electrical connector.
Ignition Coil Bolt (1) - Remove [8x]
- Electrical Connector - Disconnect [2x]
- Ignition Coil (2) - Remove [4x]
Electrical Connector @ Camshaft Carrier - Disconnect [11x]
- Retainer @ Camshaft Carrier - Disconnect [4x]
- Engine Wiring Harness (2) - Reposition
Camshaft Cover Opening Plug (1) - Remove [2x]
- Remove the M8 camshaft carrier bolt that will be under the EN-52462-A Camshaft Alignment Tool.
- NOTE:
Rotate the engine using the crankshaft balancer until the locking pins of the EN-52462-A Camshaft Alignment Tool (1) drop into the slots in the camshafts.
EN-52462-A Camshaft Alignment Tool (1) - Install
- Insert the bolt (2) of the EN-52462-A Camshaft Alignment Tool (1) into the camshaft carrier and tighten to secure the tool to the camshaft carrier.
Lock the EN-52462-A Camshaft Alignment Tool (1) by rotating the levers in direction of arrow.
Oil Level Indicator (1) - Remove
Electrical Connector (1) @ Oil Level Indicator Tube (3) - Unclip
- Oil Level Indicator Tube Bracket Bolt (2) - Remove
Oil Level Indicator Tube (1) - Remove
- Oil Level Indicator Tube O-Ring (2) - Remove and DISCARD
Retainer (1) @ Intake Manifold (2) - Unclip [5x]
- Wiring Harness (3) - Disconnect and reposition harness as necessary.
- Disconnect the fuel injector wiring harness connector.
Radiator Surge Tank Outlet Hose Clip Bracket Nut - Remove [2x]
- Radiator Surge Tank Inlet Pipe Bracket - Remove [2x]
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Disconnect
Intake Manifold Bolt (1) - Remove [7x]
Disconnect throttle body electrical connector (1)
- Intake Manifold (3) @ Charge Air Cooler Outlet Air Tube (2) - Remove
Intake Manifold Gasket (2) - Remove and DISCARD
- Remove the ground wire and M6 bolt at the back of cylinder head.
Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise and hold.
Accessory Drive Primary Belt (1) - Remove and DISCARD
- Slowly release tension on the drive belt tensioner.
Disconnect the electrical connectors at the knock sensor (3) and the coolant temperature sensor (2) under the fuel rail insulator.
- Raise and support the vehicle. Lifting and Jacking the Vehicle
Battery Negative Cable Nut (1) @ Starter Stud - Remove
- Engine Wiring Harness Retainer (2) - Disengage [2x]
- Auxiliary Generator Battery Jumper Cable (3) - Remove
Electrical Connector (1) - Disconnect
Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
Starter Stud (1) - Remove
- Starter Bolt (2) - Remove [2x]
- Starter (3) - Remove
- NOTE:
The timing pin (3) is installed into the flexplate for engine timing procedures, it can be damaged if torque is applied to the flexplate with the timing pin engaged. The timing pin must be placed in the retracted position using the handle (1) and twisting to locked position. The slide part (4) to be installed to the flexplate when torque is applied to the flexplate or crankshaft balancer bolt.
Install the slide (4) from the EN-52476 Flywheel Lock and Alignment Tool (2) to the automatic transmission flexplate.
- Lower the vehicle.
Crankshaft Balancer Bolt (1) - Remove and DISCARD
- Crankshaft Balancer (2) - Remove
- Crankshaft Balancer Bolt (1) - Install and hand tighten
Drive Belt Tensioner Bolt (1) - Remove
- Drive Belt Tensioner (2) - Remove
Remove the upper generator bolt (1).
- Loosen the lower generator bolt (2) until it is disengaged from the generator bracket.
Remove the generator (1) and the generator lower mounting bolt (2).
Radiator Inlet Hose Bracket Bolt (1) - Remove
- Radiator Inlet Hose Bracket (2) - Reposition away
- NOTE:
Intake manifold is shown transparent.
Battery Positive Cable Nut (1) @ Generator - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
Electrical Connector (1) - Disconnect
Engine Front Cover Bolt (1) - Remove [9x]
- Engine Front Cover (2) - Remove and DISCARD
Disconnect the 2 electrical connectors from the camshaft position actuator solenoids.
- Retainer (1) @ Timing Chain Upper Cover (2) - Unclip [6x]
- Engine Wiring Harness (3) - Reposition
Camshaft Position Actuator Valve Solenoid Bolt (1) - Remove [2x]
- Camshaft Position Actuator Valve Solenoid (2) - Remove
- Camshaft Position Actuator Magnet Gasket (3) - Remove and DISCARD
Camshaft Position Actuator Valve Solenoid Bolt (1) - Remove [2x]
- Camshaft Position Actuator Valve Solenoid (2) - Remove
- Camshaft Position Actuator Magnet Gasket (3) - Remove and DISCARD
Timing Chain Upper Cover Bolt - M6 (3) - Remove
- Timing Chain Upper Cover Bolt - M5 (2) - Remove [11x]
Timing Chain Upper Cover (2) - Remove
- Timing Chain Upper Cover Seal (1) - Remove and DISCARD
Mark (1) both actuator sprockets, timing chain, and the camshaft housing cover from the center of the bolt upward as shown with a paint marker or equivalent to help with installation.
Install the EN-52461 Cam Phaser Torque Reaction Tool (2) to the 2 EN-52461-100 Adapter Cam Phaser Torque Reaction Tool (3).
- Tighten the 2 bolts (1, 4) of EN-52461 Cam Phaser Torque Reaction Tool (5).
Install the EN-52461 Cam Phaser Torque Reaction Tool (5) along with the 2 EN-52461-100 Adapter Cam Phaser Torque Reaction Tool (2, 3) to the camshaft carrier.
- Tighten the 2 bolts (1, 4) of EN-52461-100 Adapter Cam Phaser Torque Reaction Tool (2, 3).
Install the EN-52461-1 Holder (1) to the holes in the camshaft sprocket.
- Check that the EN-52461-1 Holder (1) sits correctly in the hole of the camshaft sprocket.
- To take tension of the actuators and loosen timing chain. Turn the exhaust side counter clockwise to 6 N.m (53 lb in) and tighten bolt (3) just enough to hold the EN-52461-1 Holder (1) in place.
- Turn the intake side counter clockwise to 6 N.m (53 lb in) and tighten bolt (4) just enough to hold the EN-52461-1 Holder (1) in place.
Camshaft Sprocket Bolt (1) - Remove and DISCARD [2x]
Bolt (3, 4) - Loosen
- CAUTION:
Hold the camshaft sprocket firmly and squarely during camshaft sprocket bolt removal/installation. Failure to do so may result in damage to the inside of the camshaft sprocket.
Hold the intake camshaft sprocket (1) with hand from underneath the EN-52461 Cam Phaser Torque Reaction Tool (2) and pull out the EN-52461-1 Holder and the intake camshaft sprocket will drop down in hand so you can remove it.
- CAUTION:
Hold the camshaft sprocket firmly and squarely during camshaft sprocket bolt removal/installation. Failure to do so may result in damage to the inside of the camshaft sprocket.
Hold the exhaust camshaft sprocket (1) with hand from underneath the EN-52461 Cam Phaser Torque Reaction Tool (2) and pull out the EN-52461-1 Holder and the exhaust camshaft sprocket will drop down in hand so you can remove it.
Loosen the 2 bolts (1, 4) of EN-52461-100 Adapter Cam Phaser Torque Reaction Tool (5).
- Remove the EN-52461 Cam Phaser Torque Reaction Tool (5) along with the 2 EN-52461-100 Adapter Cam Phaser Torque Reaction Tool (2, 3) from the engine.
Timing Chain (1) - Remove
- Inspect the timing chain guides and replace if worn down to the base material.
Timing Chain Guide Bolt (1) - Remove [2x]
- Timing Chain Guide (2) - Remove
Timing Chain Tensioner Shoe Bolt (1) - Remove and DISCARD
- Timing Chain Tensioner Shoe (2) - Remove
Timing Chain Tensioner Bolt (1) - Remove [2x]
- Timing Chain Tensioner (2) - Remove
Remove the timing chain tensioner plunger (1) from the timing chain tensioner body (2).
- NOTE:
The ratchet mechanism will lock into place when inward pressure is released after it is turned clockwise until it is fully retracted.
Use the J-45027-1 Tensioner Tool Handle (1) to press the ratchet mechanism of the timing chain tensioner plunger (2) inward while rotating it clockwise.
- Release pressure on the ratchet mechanism of the timing chain plunger (2) until it locks into place.
- Remove the J-45027-1 Tensioner Tool Handle (1).
Install the timing chain plunger (1) into the timing chain tensioner body (2).
- NOTE:
Applying pressure to the timing chain tensioner plunger will unlock the tensioner, it will then fully extend if pressure is released prior to installing the EN-955-10A Locking Pin and will need to be reset again.
Push in and hold the timing chain tensioner plunger, insert the EN-955-10A Locking Pin (1) into the timing chain tensioner (2), then release the timing chain tensioner plunger.
Retainer (1) - Unclip [5x]
- Engine Wiring Harness (2) - Reposition away
Engine Wiring Harness Conduit Bracket Bolt (1) - Remove
- Engine Wiring Harness Conduit Nut (2) - Remove
- Engine Wiring Harness Bracket (3) - Remove
Electrical Connector (1) @ Turbocharger Bypass Valve Solenoid (2) - Disconnect
Electrical Connector (1) @ Turbocharger Wastegate Actuator - Disconnect
- Engine Wiring Harness Retainer (2) @ Turbocharger Coolant Feed and Return Pipe - Remove [2x]
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove [2x]
- Turbocharger Coolant Feed Hose Clamp (2) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove [2x]
Turbocharger Coolant Feed and Return Pipe (1) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (2) - Remove and DISCARD
Camshaft Cover Stud (1) - Remove [14x]
- Camshaft Carrier Bolt - M6 [4x] (2) - Remove
- Camshaft Carrier Bolt - M8 [4x] (3) - Remove
Camshaft Carrier (1) - Remove
- Camshaft Cover Gasket (2) - Remove and DISCARD
- NOTE:
The timing pin (3) is installed into the flexplate for engine timing procedures, it can be damaged if torque is applied to the flexplate with the timing pin engaged. The timing pin must be placed in the retracted position using the handle (1) and twisting to locked position. The slide part (4) to be installed to the flexplate when torque is applied to the flexplate or crankshaft balancer bolt.
Remove the slide (4) from the EN-52476 Flywheel Lock and Alignment Tool (1) from the automatic transmission flexplate and install the timing pin (3) by releasing the handle (1).
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (2) @ Engine Coolant Heater Exhaust Pipe - Remove
- Engine Coolant Air Bleed Hose (3) @ Engine Coolant Heater Exhaust Pipe - Remove
Engine Coolant Heater Exhaust Pipe Bolt (1) - Remove [2x]
- Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Heater Exhaust Pipe (3) @ Engine Coolant Flow Control Valve - Remove
Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]
Engine Coolant Heater Exhaust Pipe Bolt (1) - Remove
Engine Coolant Heater Exhaust Pipe Bolt (1) - Remove [2x]
- Engine Coolant Manifold Gasket (2) - Remove and DISCARD
- Engine Coolant Heater Exhaust Pipe (3) - Reposition
Turbocharger Heat Shield Bolt (1) - Remove [3x]
Turbocharger Heat Shield (1) - Remove
- Disconnect and reposition heated oxygen sensor electrical connector.
Catalytic Converter Heat Shield Bolt (1) - Remove [2x]
- Catalytic Converter Heat Shield Nut (2) - Remove
Catalytic Converter Heat Shield (1) - Remove
Turbocharger Bolt (3) - Remove and DISCARD [4x]
- The compressor air intake turbocharger (1) will remain in place.
- Turbocharger Heat Shield (2) - Remove and DISCARD
-
Loosen the bolts in the sequence shown.
Cylinder Head Bolt - M6 (1, 2, 3) - Remove [8x]
Cylinder Head Bolt - M8 (1) - Remove and DISCARD [10x]
- Cylinder Head (2) - Remove
- Cylinder Head Gasket (3) - Remove and DISCARD
- Clean all sealing surfaces.
Positive Crankcase Ventilation Oil Separator Bolt (1) - Remove [6x]
Positive Crankcase Ventilation Oil Separator (3) - Remove
- Positive Crankcase Ventilation Oil Separator Gasket (2) - Remove and DISCARD
- NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.
Remove the 8 intake valve rocker arms (1) with hydraulic valve lash adjuster (2).
Remove the 8 exhaust valve rocker arms (1) with hydraulic valve lash adjuster (2).
Valve Rocker Arm (1) @ Hydraulic Valve Lash Adjuster (2) - Remove [16x]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Injection Fuel Rail Insulator (1) - Remove
Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
- NOTE:
Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.
Install the two studs (2) from EN-49248 Injector Rail Assembly Remover (4) to the fuel injection fuel rail bolt holes and hand tighten.
- Install the EN-49248 Injector Rail Assembly Remover (4) onto each stud (2) and engage the hooks to the fuel injection fuel rail.
- Install and tighten the two nuts (1, 3).
- NOTE:
- Turn BOTH handles simultaneously, in small, even increments.
- DO NOT twist the fuel injector fuel rail while removing.
Turn both handles (1) on the EN-49248 Injector Rail Assembly Remover to disengage the fuel injection fuel rail (2).
- Remove the EN-49248 Injector Rail Assembly Remover.
- Direct Fuel Injection Fuel Rail (2) - Remove
- Fuel Injector Nozzle Housing Seal - Remove and DISCARD [8x]
Leave the oil filter in place, or oil will continue to drip.
Ensure any other retainers are disconnected.
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
If the ratchet mechanism does not lock into place and begins to extend outward, reapply inward pressure with clockwise rotation until the ratchet mechanism will not rotate further, then release into the locked position.
Reposition by rotating upward towards the rear of vehicle.