Engine Mechanical - 2.0L: Removal & Installation Ford Transit VII

Removal

Note. 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 can cause engine failure.

Scheme 1

1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Disconnect the 4 ignition coil-on-plug electrical connectors.
3. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
4. Lift up the connector boot and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
5. Disconnect the crankcase breather tube from the valve cover.
6. Detach the 6 wiring harness retainers from the valve cover stud bolts.
7. Disconnect the generator electrical connector.
8. Remove the radio interference capacitor bracket bolt.
9. Remove the radio interference capacitor ground bolt and position the bracket aside.
10. Remove the 14 valve cover retainers, the valve cover and gasket. Discard the valve cover gasket.

Scheme 2

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown in illustration.
3. Install the valve cover, a new gasket and the 14 retainers. Tighten in the sequence shown in illustration to 10 N.m (89 lb-in).
4. Position the radio interference capacitor bracket and install the bolt. Tighten to 10 N.m (89 lb-in).
5. Install the radio interference capacitor ground bolt. Tighten to 10 N.m (89 lb-in).
6. Connect the generator electrical connector.
7. Attach the 6 wiring harness retainers to the valve cover stud bolts.
8. Connect the crankcase breather tube on the valve cover.
9. Connect the CHT sensor electrical connector and install the connector boot.
10. Install the ignition coils and the 4 ignition coil-to-valve cover bolts. Tighten to 10 N.m (89 lb-in).
11. Connect the 4 ignition coil-on-plug electrical connectors.
12. Connect the CMP sensor electrical connector.

Scheme 3

ITEM DESCRIPTION

Scheme 4

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures.

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, using diamond washers between the flange faces on each part. 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. 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.

Scheme 5

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the RH wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-356740) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-356734-S38976933312010022700000) .
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

Scheme 6

1. Remove and discard the crankshaft pulley bolt and washer.
2. Remove the crankshaft pulley.
3. Remove the diamond washer and discard.

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Install a new diamond washer.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 N.m (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
5. Remove the 6 mm x 18 mm bolt.
6. Remove the Crankshaft TDC Timing Peg.
7. Remove the Camshaft Alignment Plate.
8. Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft TDC Timing Peg.
10. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
13. Remove the Camshaft Alignment Plate.
14. Remove the 6 mm x 18 mm bolt.
15. Remove the Crankshaft TDC Timing Peg.
16. Install the engine plug bolt. Tighten to 20 N.m (177 lb-in).
17. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-356734-S38976933312010022700000) .
18. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
19. Install the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-356740) .

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, using diamond washers between the flange faces on each part. 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. 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.

1. Remove the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-356734-S39171761912010022700000) and «CRANKSHAFT PULLEY»(ref-356734-S39310894042010022700000) .
2. Using the Oil Seal Remover, remove the crankshaft front oil seal.

Installation

1. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(ref-356734-S39171761912010022700000) and «CRANKSHAFT PULLEY»(ref-356734-S39310894042010022700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-356734-S33349145532010022700000) .
3. Drain the engine oil. Install the drain plug and tighten to 28 N.m (21 lb-ft).
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
5. Remove the 17 bolts and the oil pan.
6. Remove the 6 bolts and the crankshaft rear seal with retainer plate.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear seal with retainer plate and 6 bolts. Tighten in the sequence shown in illustration to 10 N.m (89 lb-in).
3. Clean and inspect all the oil pan, cylinder block and front cover flange mating surfaces.
4. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan and the 2 bolts finger-tight.
5. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 N.m (89 lb-in).
6. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 N.m (18 lb-ft).
7. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-356734-S23101949732010022700000) .
8. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-356734-S33349145532010022700000) .
9. Fill the engine with clean engine oil.

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, using diamond washers between the flange faces on each part. 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. 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.

Scheme 16

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-356734-S39310894042010022700000) .
4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Detach the 2 wiring harness retainers from the engine front cover.
5. Remove the 2 bolts and the CKP sensor.
6. Using the Oil Seal Remover, remove the crankshaft front oil seal.
7. Remove the 3 bolts and the coolant pump pulley.
8. Remove the coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-356777) .
9. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-356771) .
10. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-356734-S04792244442010022700000) .
11. Slightly raise the engine for access to the accessory drive idler pulley.
12. Remove the accessory drive idler pulley. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
13. Remove the bolts and the engine front cover.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following specifications: Tighten the 8-mm bolts to 10 N.m (89 lb-in). Tighten the 13-mm bolts to 48 N.m (35 lb-ft).
4. Install the accessory drive idler pulley. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
5. Lower the engine to the installed position.
6. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(ref-356734-S04792244442010022700000) .
7. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-356771) .
8. Install the coolant degas bottle. For additional information, refer to «ENGINE COOLING»(ref-356777) .
9. Install the coolant pump pulley and the 3 bolts. Do not tighten at this time.
10. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
11. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-356734-S39310894042010022700000) .
12. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
13. Install the CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
14. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 bolts to 7 N.m (62 lb-in).
15. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers to the engine front cover.
16. Remove the 6 mm x 18 mm bolt.
17. Tighten the coolant pump pulley bolts. Tighten to 20 N.m (177 lb-in).
18. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-356747) .

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, using diamond washers between the flange faces on each part. 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. 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.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-356734-S33031445032010022700000) .
3. Compress the timing chain tensioner in the following sequence. 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 paper clip into the hole to retain the tensioner.
4. Remove the 2 bolts and the timing chain tensioner.
5. Remove the RH timing chain guide.
6. Remove the timing chain.
7. Remove the bolts and the LH timing chain guide.
8. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur. NOTE: Intake camshaft drive gear shown in illustration, exhaust camshaft drive gear similar. Remove the bolts and the camshaft drive gears. Use the flats on the camshaft to prevent camshaft rotation.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

1. Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and bolts. Tighten to 10 N.m (89 lb-in).
3. Install the timing chain.
4. Install the RH timing chain guide. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
5. Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.
7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
9. Install the timing chain tensioner and the 2 bolts. Tighten to 10 N.m (89 lb-in). Remove the paper clip to release the piston.
10. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts. Tighten to 72 N.m (53 lb-ft).
11. Install the front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-356734-S33031445032010022700000) .

Note. 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 can cause engine failure.

Note. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-356777) .
3. Remove the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-356740) .
4. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-356734-S15173257972010022700000) .
5. Remove the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
7. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. Install the Crankshaft TDC Timing Peg.
10. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
11. Remove the front cover lower timing hole plug from the engine front cover.
12. Remove the front cover upper timing hole plug from the engine front cover.
13. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
14. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert an M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in place.
15. Remove the Camshaft Alignment Plate.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
17. Remove the timing chain from the intake camshaft drive gear.
18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.

Scheme 41

Scheme 42

1. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger-tight. Stage 2: Tighten to 7 N.m (62 lb-in). Stage 3: Tighten to 16 N.m (142 lb-in).
2. Install the Camshaft Alignment Plate.
3. Install the intake camshaft drive gear and hand-tighten the bolt.
4. Install the timing chain on the intake camshaft drive gear.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to unlock the tensioner arm.
7. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts. Tighten to 72 N.m (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the front cover upper timing hole plug. Tighten to 10 N.m (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the front cover lower timing hole plug. Install the plug and tighten to 12 N.m (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 N.m (177 lb-in).
14. Install the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE»(ref-356779) .
15. Install the RF wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-356740) .
16. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-356734-S38976933312010022700000) .
17. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-356777) .

Scheme 43

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures.

Note. 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 can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-356734-S00254332372010022700000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-356778) .
5. Connect the compressed air supply to cylinder No. 1.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multipurpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-356778) .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-356734-S00254332372010022700000) .

Note. 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 can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-356734-S00254332372010022700000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-356778) .
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multipurpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.

Scheme 44

Scheme 45

Scheme 46

1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.0L»(ref-356778) .
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-356734-S00254332372010022700000) .

Removal and Installation

Note. 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 can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-356734-S00254332372010022700000) .
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
4. To install, reverse the removal procedure.

1. Coat the valve tappets with clean engine oil prior to installation.

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, using diamond washers between the flange faces on each part. 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. 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.

Scheme 47

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-356782) .
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-356758) .
4. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(ref-356745) .
5. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-356734-S41703644142010022700000) .
6. Clean and inspect the exhaust manifold flange. For additional information, refer to exhaust manifold cleaning and inspection.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
8. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-356734-S15173257972010022700000) .
9. Remove the engine oil filter and discard.
10. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-356734-S26681867132010022700000) .
11. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-356734-S35794265892010022700000) .
12. Remove the Camshaft Alignment Plate.
13. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
14. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.
15. Remove the valve tappets.
16. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
17. Remove the 3 bolts and position the wiring harness and bracket aside.
18. Disconnect the EGR valve electrical connector.
19. Disconnect the coolant hoses from the coolant bypass.
20. Disconnect the EGR coolant hose.
21. Lower the engine and remove the Engine Support Bar.
22. Remove the 10 bolts and the cylinder head. Discard the bolts.
23. Remove and discard the head gasket.
24. Inspect the cylinder head mating surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .

Scheme 48

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Scheme 50

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. 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. Apply metal surface prep, following package directions, to remove any 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.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
4. Apply silicone gasket and sealant to the locations shown in illustration.
5. Install a new cylinder head gasket.
6. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 15 N.m (133 lb-in). Stage 3: Tighten to 45 N.m (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Install the Engine Support Bar and raise the engine.
8. Install the EGR coolant hose.
9. Connect the coolant hoses onto the coolant bypass.
10. Connect the EGR valve electrical connector.
11. Position the wire harness bracket and install the 3 bolts. Tighten to 10 N.m (89 lb-in).
12. Install the valve tappets in their original positions.
13. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated. Stage 2: Tighten to 7 N.m (62 lb-in). Stage 3: Tighten to 16 N.m (142 lb-in).
14. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-356734-S35794265892010022700000) .
15. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-356734-S38976933312010022700000) .
16. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-356734-S26681867132010022700000) .
17. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-356734-S41703644142010022700000) .
18. Install the generator. For additional information, refer to «CHARGING SYSTEM»(ref-356745) .
19. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-356758) .
20. Drain the engine oil. Install the drain plug and tighten to 28 N.m (21 lb-ft).
21. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
22. Fill the engine with clean engine oil.
23. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .

Scheme 51

ITEM DESCRIPTION

Scheme 52

ITEM DESCRIPTION

Scheme 53

ITEM DESCRIPTION

Scheme 54

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
3. Disconnect the 2 coolant hoses from the oil cooler.
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch.
6. Remove and discard the oil filter.
7. Remove the 4 bolts and the oil filter adapter.

1. Discard the gasket.

1. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 N.m (18 lb-ft).
2. Install a new oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
3. Install the EOP switch. Tighten to 15 N.m (133 lb-in).
4. Connect the EOP switch electrical connector.
5. Connect the 2 coolant hoses to the oil cooler.
6. Top off the engine with clean engine oil.
7. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-356734-S31573230222010022700000) .
3. Remove the 2 bolts and the oil pump screen and pickup tube.

1. Discard the gasket.

1. Clean and inspect all mating surfaces.
2. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 N.m (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-356734-S31573230222010022700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the oil drain plug and drain the engine oil. To install, tighten to 28 N.m (21 lb-ft).
3. Remove and discard the oil filter. To install, tighten three-fourths of a turn after the filter gasket makes contact with the oil filter adapter.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
5. Disconnect the 2 coolant hoses from the oil cooler.
6. Disconnect the Engine Oil Pressure (EOP) electrical connector.
7. Remove the 4 bolts and the oil filter adapter. NOTE: Discard the gasket. To install, tighten to 25 N.m (18 lb-ft).
8. Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler. NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) . Inspect the oil cooler. To install, tighten to 34 N.m (25 lb-ft).
9. To install, reverse the removal procedure.
10. Fill the engine with clean engine oil.
11. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .

Scheme 55

ITEM DESCRIPTION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-356744) .
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. Detach the wiring retainer.
4. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
5. Remove and discard the 7 exhaust manifold nuts.
6. Remove the exhaust manifold and discard the exhaust manifold gasket.
7. Remove and discard the 7 exhaust manifold studs.
8. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .

1. Install the 7 new exhaust manifold studs. Tighten to 17 N.m (150 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 48 N.m (35 lb-ft). Stage 1: Tighten to 48 N.m (35 lb-ft).
3. Install the exhaust manifold heat shield and the 4 bolts. Tighten to 10 N.m (89 lb-in).
4. Connect the HO2S electrical connector. Attach the wiring retainer.
5. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-356744) .

1. Remove the degas bottle bolt. To install, tighten to 8 N.m (71 lb-in).
2. Lift the coolant degas bottle off of the shock tower bracket and position it aside.
3. Install the Engine Support Bar.
4. Remove the 2 engine mount nuts. To install, tighten to 90 N.m (66 lb-ft).
5. Remove the 3 bolts and the engine mount. To install, tighten to 48 N.m (35 lb-ft).
6. To install, reverse the removal procedure.