Removal Procedure
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Intake Manifold Cover Bolt (1) - Remove
Intake Manifold Cover Insulator (1) - Remove
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Fuel Feed Pipe Bolt (1) - Remove
Disconnect the fuel feed pipe (1) from the fuel pump and the fuel feed pipe - underbody. Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (1) - Remove
Electrical Connector (1) - Disconnect [5x]
- Wiring Harness (2) - Reposition
Retainer (1) @ Upper Intake Manifold Bracket (2) - Unclip [4x]
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Radiator Surge Tank Inlet Hose Clip (2) @ Upper Intake Manifold Bracket (3) - Remove
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Upper Intake Manifold Bracket (2) - Remove
Ignition Coil Bolt (1) - Remove [8x]
- Ignition Coil (2) - Remove [4x]
Electrical Connector (1) - Disconnect [2x]
- Retainer (2) - Unclip [5x]
- Engine Wiring Harness (3) - Reposition
- Positive Crankcase Ventilation Tube (4) - Disconnect - Plastic Collar Quick Connect Fitting Service
Retainer (1) - Unclip
Camshaft Position Actuator Magnet Bolt (1) - Remove [4x]
- Camshaft Position Actuator Magnet (2) - Remove [2x]
- Camshaft Position Actuator Magnet Gasket (3) - Remove and DISCARD [2x]
Timing Chain Upper Cover Bolt (1) - Remove [9x]
- Timing Chain Upper Cover Bolt (2) - Remove
- Timing Chain Upper Cover (3) - Remove
- Timing Chain Upper Cover Seal (4) - Remove and DISCARD
Camshaft Cover Core Hole Plug (1) - Remove [2x]
- 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 EN-52462-A Camshaft Alignment Tool bolt (2) into the camshaft carrier and tighten to secure the tool to the camshaft carrier.
Rotate both handles (4) of the EN-52462-A Camshaft Alignment Tool towards the rear of the engine as shown.
- EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Install [2x]
- Install and tighten the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter bolts (3) to secure the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) to the cylinder head.
EN-52461 Camshaft Torque Reaction Tool (1) @ EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Install
- Install and tighten the 2 EN-52461 Camshaft Torque Reaction Tool bolts (3).
Engage the tangs of the EN-52461 Camshaft Torque Reaction Tool (1) to the camshaft position intake and exhaust actuator slots as shown.
- Tighten the 2 EN-52461 Camshaft Torque Reaction Tool bolts (2) to lock the camshaft position intake and exhaust actuators in place.
Loosen the camshaft position actuator valve solenoid bolts (1).
- The camshaft position actuator valve solenoid bolt (1) is loosened or removed.
- The EN-52461 Camshaft Torque Reaction Tool bolts (2, 4) are loosened.
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (2) to un-lock the camshaft position intake actuator.
Tighten the lower portion of the timing chain around the crankshaft sprocket.
- Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (1) counter-clockwise 6 N.m (53 lb in), then hold.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (2) to lock the camshaft position intake actuator securely in place.
- Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (1).
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (3) to un-lock the camshaft position exhaust actuator.
- Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (4) clockwise 6 N.m (53 lb in), then hold.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (3) to lock the camshaft position exhaust actuator securely in place.
- Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (4).
NOTE:Ensure the EN-52461 Camshaft Torque Reaction Tool bolt (2) is tightened enough that EN-52461 Camshaft Torque Reaction Tool (1) is firmly clamped and will not slip.
NOTE:Ensure the EN-52461 Camshaft Torque Reaction Tool bolt (3) is tightened enough that EN-52461 Camshaft Torque Reaction Tool (4) is firmly clamped and will not slip.
EN-52436 Timing Chain Tensioner Retention Tool (1) @ Timing Chain (2) - Install
Relieve timing chain tension from the camshaft position intake and exhaust actuators.
- The camshaft position actuator valve solenoid bolt is loosened or removed.
- The EN-52461 Camshaft Torque Reaction Tool bolts (2, 3) are loosened.
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (2) to release the camshaft position intake actuator.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (2) to lock the camshaft position intake actuator securely in place.
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (3) to release the camshaft position exhaust actuator.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (3) to lock the camshaft position exhaust actuator securely in place.
NOTE:Pressure must be applied towards the engine on the EN-52461 Camshaft Torque Reaction Tool at points (1, 4) prior to and during any time the following two conditions are simultaneously met.
Remove the camshaft position actuator valve solenoid bolts (1) and DISCARD.
- NOTE:
Hold the bottom of the camshaft postion exhaust actuator while disengaging the torque reaction tool to prevent the actuator from dropping.
Loosen the bolt (1) holding in the camshaft position exhaust actuator (3), then slide the barrel (2) of the torque reaction tool away from the camshaft position exhaust actuator (3).
- Loosen the bolt (1) holding in the camshaft position intake actuator (4), then slide the barrel (2) of the torque reaction tool away from the camshaft position intake actuator (4).
Fuel Pump Shield Bolt (1) - Remove [2x]
- Fuel Pump Shield Bolt (2) - Remove [2x]
- Fuel Injection Pump Bracket (3) - Remove
- 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 Pump Insulator (1) - Remove
Nut @ Fuel Feed Intermediate Pipe (1) - Loosen [2x]
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- Electrical Connector @ Fuel Pump - Disconnect
- 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 Stud (1) - Remove [2x]
- Fuel Pump (2) - Remove
- Fuel Pump Seal (3) - Remove and DISCARD
- Valve Lifter Follower (4) - Remove
Electrical Connector (1) @ Camshaft Carrier (3) - Disconnect [6x]
- Electrical Connector (2) @ Camshaft Carrier (3) - Disconnect [6x]
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Remove
- CAUTION:
The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.
NOTE:Disconnecting the tamper resistant connections will damage the positive crankcase ventilation tube, it must be replaced after removal.
Positive Crankcase Ventilation Tube (1) - Remove and DISCARD
- Remove the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapters, and the EN-52461 Camshaft Torque Reaction Tool.
Camshaft Cover Stud (1) - Remove
- Camshaft Cover Stud (2) - Remove [16x]
- Camshaft Cover Bolt (3) - Remove [5x]
- Camshaft Carrier (4) - Remove
- Camshaft Cover Gasket (5) - Remove and DISCARD
EN-52462 - A Camshaft Tool (1) - Remove
Camshaft Bearing Cap Bolt (1) - Remove [25x]
- Camshaft Bearing Lower Cap (2) - Remove
- Camshaft Bearing Lower Cap (3) - Remove
- Camshaft Bearing Front Cap (4) - Remove
- Ensure the 5 engine front cover locating pins (5) remain in place.
Intake Camshaft (1) - Remove
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses Warning .
Use pry points indicated by arrows.
Ensure the camshaft carrier and cylinder head face are clean and free from RTV prior to installing the EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter.
Hold the camshaft position actuator firmly and squarely during camshaft position actuator valve solenoid bolt removal/installation. Failure to do so may result in damage to the inside of the camshaft position actuator.
Pressure must be applied towards the engine on the EN-52461 Camshaft Torque Reaction Tool at points (3) prior to and during any time the following two conditions are simultaneously met.
Hold the bottom of the camshaft postion intake actuator while disengaging the torque reaction tool to prevent the actuator from dropping.