Engine - Plug-In Hybrid Electric Vehicle (PHEV)
WARNING: This page is about a different variant/trim than selected.
Special Tool(s) / General Equipment
| 205-153 (T80T-4000-W) Handle | |
|---|---|
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 303-1247VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM | |
| 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH | |
| 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 | |
| 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW |
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. 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. All parts must be thoroughly cleaned and 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.
NOTE:
If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
NOTE:
Refer to the exploded views in Description and Operation.
- Remove the bolts and the damper.
- Remove the bolts and the flywheel.
- Discard the bolts.
- Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.
- Refer to: Quick Release Coupling
.
-
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: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
-
NOTE: The VCT solenoid seal should only be replaced if it is damaged.
Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer.205-153 (T80T-4000-W) Handle.
-
NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
-
NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.
-
NOTE: The Crankshaft TDC Timing Peg 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 disassembly.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
-
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 Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).NOTE: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.
Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
-
NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.
If equipped, remove the diamond washer.
-
NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
-
NOTE: If equipped with cast iron timing chain tensioner.
- Using a small pick, release and hold the ratchet mechanism.
- While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
- Insert a holding pin into the hole to retain the tensioner.
-
NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).NOTE: If equipped with cast iron timing chain tensioner.
Remove the bolts and the timing chain tensioner.
-
NOTE: If equipped with aluminum timing chain tensioner.
Remove the bolts and the timing chain tensioner.
-
NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.NOTE: Using the flats on the camshaft to prevent camshaft rotation.
-
NOTE: The oil pump chain sprocket must be held in place.
-
NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.NOTE: Mark the location and orientation of each camshaft bearing cap.
Loosen one turn at a time. Repeat until all the tension is released.
-
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.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.
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion
-
NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.
If equipped, remove the diamond washer.
- Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
-
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
-
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
-
NOTE: Mark the position of the parts, so they can be installed in their original positions.
- Remove in the sequence shown.
-
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
-
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.NOTE: The center bulkhead has the thrust bearing.
-
NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.NOTE: The front bulkhead does not have an oil squirter.