Valve Tappets: Disassembly: Engine

	3 Jaw Puller 303-D121  or equivalent
	Handle 205-153  (T80T-4000-W)
	Remover, Crankshaft Rear Oil Seal 303-519  (T95P-6701-EH)
	Remover, Fuel Injector 310-206
	Remover, Oil Seal 303-409  (T92C-6700CH)
	Remover, VCT Spark Plug Tube Seal 303-1247  /1
	Slide Hammer 307-005  (T59L-100-B)
	Tool, Camshaft Holding 303-1248

All vehicles 

1. Remove the 8 bolts and the flexplate.
2. Remove the crankshaft sensor ring.

   Cast aluminum (early build) crankshaft rear seal retainer plates 

3. Special Tool(s): Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) and Slide Hammer 307-005 (T59L-100-B).

   All vehicles 

4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

   Install the General Equipment: Engine Stand.

5. If equipped, remove the block heater heat shield.
6. If equipped, disconnect the block heater electrical connector.
   • Remove the block heater wiring harness from the engine.
7. Remove the 3 bolts and the accessory drive belt tensioner.
8. Disconnect the LH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
9. NOTE: Index-mark the hoses for installation.

   Remove the turbocharger wastegate regulating valve hoses from the RH CAC  tube and turbocharger wastegate regulating valve.

   • Disconnect the turbocharger wastegate regulating valve electrical connector.
10. Disconnect the RH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
11. NOTE: Index-mark the CAC  tube position for reference during installation.

    Loosen the clamp and remove the LH turbocharger intake tube from the LH turbocharger.

12. NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Remove the nut from the RH valve cover stud bolt and remove the RH turbocharger intake tube.

13. NOTE: Index-mark the CAC  tube position for reference during installation.

    Loosen the clamp and remove the RH CAC  tube from the RH turbocharger.

14. NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Remove the RH CAC  tube nut from the intake manifold and remove the RH CAC  tube and turbocharger intake tube as an assembly.

15. Remove the lower radiator hose from the thermostat housing.
16. Disconnect the 2 quick connect couplings and remove the PCV tube. Refer to QUICK CONNECT COUPLING .
17. Remove the noise insulator shield for the fuel injection pump and remove the oil level indicator.
18. Disconnect the Throttle Position (TP) sensor, electronic TB, LH Variable Camshaft Timing (VCT) solenoid and the 3 ignition coil-on-plugs electrical connectors.
    • Detach all the wiring harness retainers from the LH valve cover and stud bolts.
19. Remove the nut, bolt and the generator.
    • Remove the generator stud.
20. Remove the stud bolt, nut and the A/C compressor.
21. Remove the A/C compressor mounting stud from the oil pan.
22. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP  wiring harness retainer from the engine block.
23. Remove the 3 bolts and the oil filter adapter.
24. Remove the oil filter adapter gasket and discard.
25. Remove the EOP  switch.
26. Disconnect the Knock Sensor (KS) sensor electrical connector.
27. Disconnect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.
    • Detach and disconnect the 2 fuel injector wiring harness electrical connectors and the 2 wiring harness retainers.
28. Remove the coolant tube and remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.
29. Disconnect the 2 turbocharger coolant hoses from the intake manifold and disconnect the CMP  sensor electrical connector.
    • Detach the wiring harness retainer.
30. Disconnect the RH VCT  solenoid and the 3 ignition coil-on-plug electrical connectors.
    • Detach all the wiring harness retainers.
31. Remove the 2 bolts and the 2 ground wire from the RH cylinder head and the battery wiring harness.
    • Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
32. Remove the bolt and the RH CMP  sensor.
    • Remove the CHT  sensor.
33. Disconnect the LH CMP  sensor electrical connector and remove the coolant tube retainer nut.
    • Detach the 2 wiring harness retainers.
34. Remove the bolt and the LH CMP  sensor and remove the stud bolt and the ground wire.
35. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

    Remove the 12 bolts and the intake manifold.

    • Clean and inspect all sealing surfaces.
36. Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.
37. Remove the 3 bolts and the LH exhaust manifold heat shield.
38. Remove the LH oil supply tube secondary latch.
39. Remove the LH oil supply tube from the quick connect fitting.
40. Remove the 3 banjo bolts and the LH turbocharger coolant tubes and oil tube.
    • Disconnect the turbocharger wastegate regulating valve hose from the LH turbocharger assembly.
41. Discard the oil supply tube washer and filter.
42. Discard the turbocharger coolant tubes washers.
43. Remove the 2 bolts and the LH turbocharger oil return tube from the oil pan.
44. Discard the gasket and O-ring seals.
45. Remove the 2 bolts and the lower LH turbocharger-to-cylinder block bracket.
46. Remove the 2 bolts and the upper LH turbocharger bracket-to-cylinder block bracket.
47. Remove the 8 LH exhaust manifold nuts and the exhaust manifold and turbocharger as an assembly.
    • Discard the nuts.
    • Clean and inspect the LH exhaust manifold. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
48. NOTE: 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.

    Remove the 8 LH exhaust manifold studs and exhaust manifold gasket.

    • Discard the studs and gasket.
    • Clean the exhaust manifold mating surface of the cylinder head with metal surface prep.

      Follow the directions on the packaging.

49. Remove the nut and the heat shield.
50. Remove the wiring harness grommet.
51. Disconnect the CKP  sensor electrical connector and remove the stud bolt and the engine wiring harness.
52. Remove the bolt and the CKP  sensor.
53. Remove the RH oil supply tube secondary latch and the stud bolt and the HO2S  bracket.
54. Remove the RH oil supply tube from the quick connect fitting.
55. Remove the RH coolant tube bracket-to-cylinder head bolt.
56. Remove the 5 bolts and the 2 upper RH exhaust manifold heat shields.
57. Remove the 3 banjo bolts and the RH turbocharger coolant tubes and oil tube.
    • Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.
58. Discard the oil supply tube washer and filter.
59. Discard the turbocharger coolant tubes washers.
60. Remove the 2 bolts and the RH turbocharger oil return tube from the cylinder block.
61. Discard the gasket and O-ring seals.
62. Remove the 3 bolts and the upper turbocharger-to-cylinder block bracket.
63. Remove the 8 nuts and the RH exhaust manifold and turbocharger as an assembly.
    • Discard the nuts.
    • Clean and inspect the RH exhaust manifold. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
64. NOTE: 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.

    Remove and the 8 RH studs and exhaust manifold gasket.

    • Discard the studs and gasket.
    • Clean the exhaust manifold mating surface of the cylinder head with metal surface prep.

      Follow the directions on the packaging.

65. Remove the 2 bolts and the RH engine lifting eye.
66. Remove the pin-type retainer and the cover.
67. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
68. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
69. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the flare nut.

    Remove the nut for from the LH valve cover stud bolt and remove the high pressure fuel tube flare nuts from the fuel injection pump and fuel rail.

    • Discard the tube and nut.
70. Remove the 2 bolts and the fuel injection pump.
    • Discard the bolts.
71. Discard the O-ring seal.
72. Remove the fuel injection pump mounting plate.
73. Remove the fuel injection pump roller tappet.
74. Inspect the fuel injection pump roller tappet. REFER to FUEL INJECTION PUMP ROLLER TAPPET INSPECTION .
75. NOTE: It is very important to note the routing of the wiring harness on the fuel rails and index-mark the locations of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct wire harness routing and tie strap positioning for installation.
    NOTE: Use compressed air to remove any dirt or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

    Carefully cut and remove the fuel rail wire harness tie straps and disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.

76. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.

    Remove the 6 bolts and the LH fuel rail.

    • Discard the bolts.
77. Remove the 6 bolts and the RH fuel rail.
    • Discard the bolts.
78. NOTE: RH shown in illustration, LH similar.

    Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harnesses.

79. NOTE: LH  shown in illustration, RH  similar.

    Remove any of the fuel injectors that remained in the fuel rail.

80. Discard the clips.
81. Special Tool(s): Slide Hammer 307-005 (T59L-100-B) and Remover, Fuel Injector 310-206. Remove any fuel injectors that did not come out with the fuel rail.
82. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the 3 bolts and the 3 RH ignition coils-on-plugs.

83. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the 3 bolts and the 3 LH ignition coils-on-plugs.

84. Loosen the 10 stud bolts and remove the LH valve cover.
    • Discard the gasket.
85. Remove the LH valve cover gasket and discard.
86. Loosen the 11 stud bolts and remove the RH valve cover.
    • Discard the gasket.
87. Remove the RH valve cover gasket and discard.
88. NOTE: VCT  solenoid seal removal shown in illustration, spark plug tube seal removal similar. Inspect the VCT  solenoid seals and the spark plug tube seals. Install new seals if damaged.
    • Special Tool(s): Remover, VCT  Spark Plug Tube Seal 303-1247/1 and Handle 205-153 (T80T-4000-W).
89. Remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
90. Remove the crankshaft pulley.
91. Special Tool(s): Remover, Oil Seal 303-409 (T92C-6700CH).
92. Remove the 3 bolts and the engine mount bracket.
93. Remove the 22 engine front cover bolts.
94. 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.
95. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration.
96. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

    Install the Special Tool(s): Tool, Camshaft Holding 303-1248.

97. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Special Tool(s): Tool, Camshaft Holding 303-1248.

98. Remove the 3 bolts and the RH VCT  housing.
99. Remove the 3 bolts and the LH VCT  housing.
    NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
100. Mark the timing chain link that aligns with the timing mark on the RH intake VCT  assembly as shown in illustration.
101. Mark the timing chain link that aligns with the timing mark on the LH intake VCT  assembly as shown in illustration.
102. 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 in illustration.

103. Remove the 2 bolts and the primary timing chain tensioner.
104. Remove the primary timing chain tensioner arm.
105. Remove the 2 bolts and the lower LH primary timing chain guide.
106. Remove the primary timing chain.
107. Remove the crankshaft timing chain sprocket.
108. Remove the bolt and the upper LH primary timing chain guide.
109. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
110. NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

     Remove the LH VCT  assembly bolt and the LH exhaust camshaft sprocket bolt.

     • Discard the bolts.
     • Remove the LH VCT  assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
111. 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 Special Tool(s): Tool, Camshaft Holding 303-1248.

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

     Verify the LH camshafts are in the neutral position.

113. Remove the 2 bolts and the LH secondary timing chain tensioner.
114. 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.
115. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
116. NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

     Remove the RH VCT  assembly bolt and the RH exhaust camshaft sprocket bolt.

     Discard the specified component. Follow local disposal regulations.

     • Discard the bolts.
     • Remove the RH VCT  assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
117. Remove the Special Tool(s): Tool, Camshaft Holding 303-1248.
118. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

     Rotate the RH camshafts counterclockwise to the neutral position.

119. Remove the 2 bolts and the RH secondary timing chain tensioner.
120. Remove the bolt and the RH timing chain guide.
121. 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.
122. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
     NOTE: LH shown in illustration, RH similar.

     Remove the 24 valve tappets from the cylinder heads.

123. Inspect the valve tappets. REFER to VALVE TAPPET INSPECTION .
124. NOTE: LH shown in illustration, RH similar.

     Remove the M6 bolt from each cylinder head and discard.

125. NOTE: 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.
     NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
     NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a torque-to-yield design and cannot be reused.
     NOTE: LH shown in illustration, RH similar.

     Remove the 8 bolts from each cylinder head.

     • Discard the bolts.
     • Remove the cylinder heads.
126. NOTE: LH shown in illustration, RH similar.

     Remove the cylinder head gasket from each cylinder head and discard.

127. 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.
     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: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

     Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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.
128. 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 CYLINDER HEAD DISTORTION , and CYLINDER BLOCK DISTORTION .
129. Remove the coolant inlet tube.
130. Remove the coolant inlet tube O-ring seal and discard.
131. Remove the 2 bolts and the KS  .
132. Remove the 8 bolts and the coolant pump.
133. Remove the 16 oil pan bolts.
134. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.
135. Remove the 2 bolts and the oil pump screen and pickup tube.
136. Remove and discard the O-ring seal.
137. Remove the 3 bolts and the oil pump.

     Cast aluminum (early build) crankshaft rear seal retainer plate 

138. Remove the 8 crankshaft rear seal retainer bolts.
139. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
     • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
       • Remove the crankshaft rear seal retainer.

     Stamped steel (late build) crankshaft rear seal retainer plate 

140. Remove the 8 bolts and the crankshaft rear seal retainer plate.
     • Discard the plate and seal assembly.

     All vehicles 

141. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

     Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2 inch, white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM.

     • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
142. 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.
143. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

     Remove the bolts in the sequence shown in illustration.

     • Discard the bolts.
     • Remove the main bearing cap support brace.
144. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.
     NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.

     Remove the 12 connecting rod cap bolts and 6 cap.

145. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

     Remove the piston/rod assembly from the engine block.

146. Repeat the previous step until all the piston/rod assemblies are removed from the engine block.
147. NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
     NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

     Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration.

     • Discard the bolts.
148. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
     NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.

     Remove the 4 main bearing caps.

149. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
150. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

     Remove the 4 crankshaft main bearings from the main bearing caps.

151. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

     Remove the crankshaft.

152. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
153. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

     Remove the 4 crankshaft main bearings from the cylinder block.

154. Remove the 6 piston oil cool valves.
155. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. Refer to ENGINE SYSTEM - GENERAL INFORMATION for SPECIFICATIONS , and appropriate procedures in GENERAL PROCEDURES .
156. NOTE: 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.
     NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® 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 the gasket.

     Clean the sealing surfaces of the cylinder block 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.