Part 3

Camshaft













Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTICE: 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 may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

106. Detach the 2 wire harness-to-intake manifold retainers.





107. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.





108. Disconnect the 2 turbocharger coolant hoses from the intake manifold.





109. NOTICE: 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.

- Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.

- Clean and inspect all sealing surfaces.





110. Disconnect the RH VCT solenoid electrical connector and detach the 2 wiring harness retainers.





111. Disconnect the 3 RH ignition coil-on-plug electrical connectors.





112. Detach all the wiring harness retainers from the RH valve cover and stud bolts.

Early build vehicles

113. Remove the nut for the high pressure fuel tube from the LH valve cover stud bolt.





Late build vehicles

114. Remove the high pressure fuel tube bolt from the LH cylinder head.





All vehicles

115. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.

Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails and remove the high pressure fuel tube assembly.





116. Remove the 2 bolts and the fuel injection pump.





117. Remove the fuel injection pump mounting plate.





118. NOTE: Valve cover is removed for clarity.

Remove the fuel injection pump roller tappet.

- Inspect the fuel injection pump roller tappet. For additional information, refer to Fuel Delivery and Air Induction.





119. 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 coil-on-plugs.





120. 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 coil-on-plugs.





121. Loosen the 10 stud bolts and remove the LH valve cover.
- Discard the gasket.





122. Loosen the 11 stud bolts and remove the RH valve cover.
- Discard the gasket.





123. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.

Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





124. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





125. Remove the 3 bolts and the accessory drive belt tensioner.





126. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.





127. Using the 3 Jaw Puller, remove the crankshaft pulley.





128. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





129. Remove the HO2S connector bracket stud bolt from the engine front cover.





130. NOTE: Only use hand tools to remove the studs.

Remove the 2 engine mount studs.





131. Remove the 3 bolts and the engine mount bracket.





132. Remove the 22 engine front cover bolts.





133. 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.





134. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.

- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

135. NOTICE: 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.

NOTICE: Do not use wire brushes, power abrasive discs or 3M(TM) Roloc(R) 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 sealant, including any sealant from the inner surface of the cylinder block and cylinder head.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan 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.

Engines equipped with early build RH timing chain guides

136. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.





Engines equipped with late build/replacement RH timing chain guides

137. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.





All camshafts

138. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

Install the Camshaft Holding Tool onto the flats of the LH camshafts.





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

Install the Camshaft Holding Tool onto the flats of the RH camshafts.





140. Remove the 3 bolts and the RH VCT housing.





141. Remove the 3 bolts and the LH VCT housing.





142. Remove the 2 bolts and the primary timing chain tensioner.





143. Remove the primary timing chain tensioner arm.





144. Remove the 2 bolts and the lower LH primary timing chain guide.





145. Remove the primary timing chain.





LH camshafts

146. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





147. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
- Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.





148. 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 Camshaft Holding Tool from the LH camshafts.





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

Verify the LH camshafts are in the neutral position.





150. 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.





RH camshafts

151. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.





152. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
- Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.





153. Remove the Camshaft Holding Tool from the RH camshafts.





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

Rotate the RH camshafts counterclockwise to the neutral position.





155. 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.