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Engine Mechanical - 3.5L: Removal & Installation Lincoln MKZ I рестайлинг

Mechanical 127 illustrations ~8594 words

Removal

  1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .
  2. Disconnect the Throttle Body (TB) electrical connector.
  3. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-355987) .
  4. Disconnect the brake booster vacuum hose from the intake manifold.
  5. Disconnect the PCV tube from the PCV valve.
  6. Detach all the wiring harness retainers from the upper intake manifold.
  7. If equipped, detach the cylinder block heater wiring harness retainer from the upper intake manifold.
  8. Remove the upper intake manifold support bracket bolt.
  9. Remove the 6 bolts and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

Scheme 1

Scheme 1: Installation
Scheme 1: Installation
  1. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). 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.
  2. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
  3. If equipped, attach the cylinder block heater wiring harness retainer to the upper intake manifold.
  4. Attach all the wiring harness retainers to the upper intake manifold.
  5. Connect the PCV tube to the PCV valve.
  6. Connect the brake booster vacuum hose to the intake manifold.
  7. Connect the EVAP tube to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-355987) .
  8. Connect the TB electrical connector.
  9. Install the ACL outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .

Scheme 2

Scheme 2: Lower Intake Manifold
Scheme 2: Lower Intake Manifold
ItemPart NumberDescription
1W708607Thermostat housing-to-lower intake manifold bolt
2W503279Thermostat housing-to-lower intake manifold bolt
39439Lower intake manifold gasket (8 required)
48A571Thermostat housing gasket
5W503279Lower intake manifold bolt (10 required)
69K461Lower intake manifold

ITEM DESCRIPTION TABLE

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-355922) .
  2. Remove the fuel rail. For additional information, refer to «REMOVAL»(ref-355994-S36910121072010013000000) .
  3. Drain the cooling system. For additional information, refer to «DRAINING»(ref-355972-S18230589312010013000000) .
  4. Remove the 2 thermostat housing-to-lower intake manifold bolts.
  5. Remove the 10 bolts and the lower intake manifold. Remove and discard the intake manifold and thermostat housing gaskets. Clean and inspect all sealing surfaces.

Scheme 3

Scheme 3: Installation
Scheme 3: Installation
  1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). 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.
  2. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
  3. Install the fuel rail. For additional information, refer to «INSTALLATION»(ref-355994-S12452897742010013000000) .
  4. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-355972-S37681702192010013000000) .

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, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 4

Scheme 4: Removal
Scheme 4: Removal

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Scheme 7
  1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .
  2. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-355995) .
  3. Remove the oil level indicator.
  4. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.
  5. Detach the 2 wiring harness retainers.
  6. Disconnect the 2 engine control wiring harness electrical connectors.
  7. Remove the 2 nuts and the wiring harness retaining bracket.
  8. Detach all of the wiring harness retainers from the valve cover and the stud bolts.
  9. Disconnect the 3 LH fuel injector electrical connectors. Early build vehicles
  10. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket. Late build vehicles
  11. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket. All vehicles
  12. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s). NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
  13. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

Installation

All vehicles

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Scheme 8: Installation
Scheme 8: Installation

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  1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, VCT solenoid seal installation similar.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Late build vehicles
  3. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Early build vehicles
  4. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). All vehicles
  5. Connect the 3 LH fuel injector electrical connectors.
  6. Attach all of the wiring harness retainers to the valve cover and the stud bolts.
  7. Install the wiring harness retaining bracket and the 2 nuts. Tighten to 4 Nm (35 lb-in).
  8. Connect the 2 engine control wiring harness electrical connectors.
  9. Attach the 2 wiring harness retainers.
  10. Connect the LH VCT solenoid electrical connector.
  11. Install the oil level indicator.
  12. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-355995) .
  13. Install the ACL outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .

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, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 12

Scheme 12: Removal
Scheme 12: Removal
  1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-355995) .
  2. Remove the power steering fluid reservoir. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355943-S13224718292010013000000) .
  3. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
  4. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector and retainer.
  5. Remove the PSP hose bracket nut from the valve cover stud bolt and position the bracket aside.
  6. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
  7. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
  8. Disconnect the 3 RH fuel injector electrical connectors.
  9. Detach all of the wiring harness retainers from the valve cover and the stud bolts.
  10. Remove the A/C tube retaining clamp bolt.
  11. Remove the 2 A/C tube retaining clamp bolts. Early build vehicles
  12. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. NOTE: It is necessary to reposition the A/C tubes to remove the valve cover. Late build vehicles
  13. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. NOTE: It is necessary to reposition the A/C tubes to remove the valve cover. All vehicles
  14. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s). NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
  15. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

All vehicles

Scheme 13

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Scheme 15
  1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, VCT solenoid seal installation similar.
  2. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Late build vehicles
  3. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Early build vehicles
  4. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
  5. Position the A/C tubes and install the 2 retaining clamp bolts. Tighten to 10 Nm (89 lb-in).
  6. Install the A/C tube retaining clamp bolt. Tighten to 8 Nm (71 lb-in).
  7. Attach all of the wiring harness retainers to the valve cover and the stud bolts.
  8. Connect the 3 LH fuel injector electrical connectors.
  9. Connect the LH VCT electrical connector.
  10. Connect the RH HO2S electrical connector.
  11. Install the PSP hose bracket and nut. Tighten to 9 Nm (80 lb-in).
  12. Connect the RH CMS electrical connector and retainer.
  13. Connect the PSP switch electrical connector.
  14. Install the power steering fluid reservoir. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355943-S13224718292010013000000) .
  15. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.5L»(ref-355995) .

Scheme 16

Scheme 16: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
Scheme 16: Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
ItemPart NumberDescription
1W701512Crankshaft pulley bolt
2N806165Washer
36316Crankshaft pulley
46700Crankshaft front seal

ITEM DESCRIPTION TABLE

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

Removal and Installation

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
  2. Remove the transaxle. For additional information, refer to «TRANSAXLE»(ref-355918-S00100076902010013000000) .
  3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft). NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
  4. To install, reverse the removal procedure.
  5. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

All vehicles

Scheme 17

Scheme 17: Removal
Scheme 17: Removal
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
  2. If equipped, remove the 6 screws and the underbody shield.
  3. Remove and discard the engine oil filter. Early build vehicles
  4. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal. Clean and inspect all sealing surfaces. Late build vehicles
  5. Remove the 3 bolts and the oil filter adapter. Discard the gasket. Clean and inspect all sealing surfaces.

Late build vehicles

  1. Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten to 10 Nm (89 lb-in). Early build vehicles
  2. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in). All vehicles
  3. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  4. If equipped, install the 6 screws and the underbody shield.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
  2. If equipped, remove the 6 screws and the underbody shield.
  3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
  4. Remove the EOP switch. To install, tighten to 18 Nm (159 lb-in).
  5. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.
WARNINGDo 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.

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, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

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Scheme 59
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-355987-S17471545942010013000000) .
  3. Recover the A/C system. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-355932-S31251914202010013000000) .
  4. Remove the accessory drive belt and the power steering belt. For additional information, refer to «REMOVAL»(ref-355937-S42663157132010013000000) .
  5. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to «REMOVAL»(ref-355956-S19151780662010013000000) .
  6. If equipped, remove the 6 screws and the underbody shield.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
  8. Drain the cooling system. For additional information, refer to «DRAINING»(ref-355972-S18230589312010013000000) .
  9. Remove the degas bottle. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355972-S07928583072010013000000) .
  10. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .
  11. Remove the battery tray. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355968-S25610670162010013000000) .
  12. Disconnect the 2 engine wiring harness electrical connectors.
  13. Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket.
  14. Remove the 2 nuts and the battery cables from the positive battery cable.
  15. Remove the bolt and position aside the ground wire.
  16. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
  17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  18. Disconnect the transaxle control cable from the control lever.
  19. Remove the 3 nuts and position the transaxle control cable bracket aside.
  20. Remove the bolt and position the ground wire aside.
  21. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
  22. Detach the coolant tube retainer clips from the A/C tube.
  23. Remove the nut and disconnect the A/C tube from the condenser. Discard the O-ring seals.
  24. Remove the 2 A/C tube retaining clamp bolts.
  25. Remove the A/C tube bracket bolt.
  26. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
  27. Detach the 2 wiring harness retainers.
  28. Disconnect the 2 engine wiring harness electrical connectors.
  29. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
  30. Remove the oil level indicator.
  31. Disconnect the hose from the power steering reservoir. Detach the pin-type retainer from the engine mount brace.
  32. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
  33. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-355987) .
  34. Remove the bolt and the ground wire from the engine mount brace.
  35. Remove the 3 bolts and the engine mount brace.
  36. Disconnect the PCM electrical connectors and pin-type retainers.
  37. Remove the Power Steering Pressure (PSP) hose bracket bolt.
  38. Remove and discard the PSP banjo bolt and the 2 seals from the steering gear.
  39. Using a suitable holding device, hold the steering wheel in the straight-ahead position. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
  40. Remove the 2 nuts and the steering joint cover.
  41. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to «REMOVAL»(ref-355944-S31813300882010013000000) . NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
  42. Remove the 4 screws and position the LH fender splash shield aside.
  43. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
  44. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
  45. Disconnect the transaxle cooler hoses.
  46. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
  47. Remove and discard the engine oil filter.
  48. Remove the 6 nuts and the Y-pipe assembly. Discard the gaskets and nuts. All-Wheel Drive (AWD) vehicles
  49. Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire. NOTE: Index-mark the driveshaft for installation. All vehicles
  50. Remove the engine roll restrictor-to-subframe through bolt.
  51. Remove the cotter pins and nuts from the tie-rod ends. NOTE: LH shown in illustration, RH similar.
  52. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles. NOTE: LH shown in illustration, RH similar.
  53. Remove the nuts and separate the stabilizer bar links from the struts. NOTE: LH shown in illustration3, RH similar.
  54. Position the Powertrain Lift under the subframe assembly.
  55. Remove the 4 subframe bracket-to-body bolts. NOTE: LH shown in illustration, RH similar.
  56. Remove the 2 subframe nuts and the 2 subframe brackets. NOTE: LH shown in illustration, RH similar.
  57. Remove the 2 front subframe nuts. NOTE: LH shown in illustration, RH similar.
  58. Using the Powertrain Lift, lower the subframe assembly from the vehicle. Front Wheel Drive (FWD) vehicles
  59. Remove the 2 RH catalytic converter bracket bolts.
  60. Remove the 2 nuts and remove the RH catalytic converter bracket. All vehicles
  61. Install the Powertrain Lift and Universal Adapter Brackets. NOTE: Position a block of wood under the transaxle.
  62. Remove the transaxle support insulator through bolt.
  63. Remove the transaxle support insulator bracket bolt and the 2 nuts.
  64. Remove the 4 engine mount nuts. Remove the 2 engine mount spacers.
  65. Remove the nut, 2 bolts and the engine mount.
  66. Lower the engine and transaxle assembly from the vehicle.
  67. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
  68. If equipped, detach the block heater wiring harness retainers from the PSP hose and the power steering reservoir hose.
  69. Disconnect the PCV hose from the PCV valve.
  70. Disconnect the Throttle Body (TB) electrical connector.
  71. Detach the wiring harness retainers from the upper intake manifold.
  72. Remove the upper intake manifold support bracket bolt.
  73. Remove the 6 bolts and the upper intake manifold. Discard the gaskets. 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.
  74. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
  75. Disconnect the PSP switch electrical connector.
  76. Disconnect the RH VCT solenoid electrical connector.
  77. Disconnect the 3 RH coil-on-plug electrical connectors.
  78. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  79. Disconnect the LH VCT solenoid electrical connector.
  80. Disconnect the 3 LH coil-on-plug electrical connectors.
  81. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  82. Remove the 6 bolts and the 6 coil-on-plugs. NOTE: LH shown in illustration, RH similar.
  83. Detach the PSP hose retainer from the engine lifting eye.
  84. Remove the PSP hose bracket nut and position the PSP hose aside.
  85. Remove the 2 nuts and the wiring harness retaining bracket. Early build vehicles
  86. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
  87. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
  88. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
  89. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
  90. 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). NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
  91. Remove the 3 bolts and position the power steering pump aside.
  92. Remove the 3 bolts and the accessory drive belt tensioner.
  93. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
  94. Using the 3 Jaw Puller, remove the crankshaft pulley.
  95. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
  96. Remove the 2 bolts and the engine mount bracket.
  97. Remove the 2 engine mount studs. NOTE: Only use hand tools to remove the studs.
  98. Remove the 3 bolts and the engine mount bracket.
  99. Remove the 22 engine front cover bolts.
  100. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence. 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.
  101. Clean the engine front cover using a 3M Roloc® 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. NOTE: Only use a 3M Roloc® 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.
  102. Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. 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. Make sure the 2 locating dowel pins are seated correctly in the cylinder block. 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.

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.

All camshafts

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Scheme 65
  1. Remove the engine front cover. For additional information, refer to «Removal and Installation»(ref-355916-S07935742642010060800000) . Engines equipped with early build RH timing chain guides
  2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
  3. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
  4. Install the Camshaft Holding Tool onto the flats of the LH camshafts. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
  5. Install the Camshaft Holding Tool onto the flats of the RH camshafts. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
  6. Remove the 3 bolts and the RH VCT housing.
  7. Remove the 3 bolts and the LH VCT housing.
  8. Remove the 2 bolts and the primary timing chain tensioner.
  9. Remove the primary timing chain tensioner arm.
  10. Remove the 2 bolts and the lower LH primary timing chain guide.
  11. Remove the primary timing chain. LH camshafts
  12. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  13. 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. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  14. Remove the Camshaft Holding Tool from the LH camshafts. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
  15. Verify the LH camshafts are in the neutral position. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
  16. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. RH camshafts
  17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
  18. 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. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  19. Remove the Camshaft Holding Tool from the RH camshafts.
  20. Rotate the RH camshafts counterclockwise to the neutral position. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
  21. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

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. 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.

All vehicles

Scheme 66

Scheme 66: Removal and Installation
Scheme 66: Removal and Installation

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Scheme 90
  1. Remove the RH camshafts. For additional information, refer to «Removal and Installation»(ref-355916-S04720268482010060800000) .
  2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  3. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
  4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
  5. Remove the bolt and the Power Steering Pressure (PSP) tube and bracket assembly.
  6. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
  7. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
  8. Disconnect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector.
  9. Remove the 2 LH catalytic converter bracket bolts.
  10. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
  11. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block. All-Wheel Drive (AWD) vehicles
  12. Remove the 2 RH catalytic converter bracket bolts. All vehicles
  13. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
  14. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  15. Remove the 3 bolts and the RH exhaust manifold heat shield.
  16. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
  17. Clean and inspect the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
  18. Remove and discard the 6 RH exhaust manifold studs. Engines equipped with early build RH timing chain guides
  19. Remove the 2 bolts and the RH primary timing chain guide. Engines equipped with late build/replacement RH timing chain guides
  20. Remove the 2 bolts and the RH primary timing chain guide. All vehicles
  21. Remove the 2 bolts and the RH secondary timing chain tensioner.
  22. Remove the 2 bolts and the engine lifting eye.
  23. Remove the bolt and the upper intake manifold support bracket. NOTE: Index-mark the location of the bracket on the cylinder head for installation.
  24. Remove the bolt and the RH CMP sensor.
  25. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  26. Disconnect the coolant bypass hose from the thermostat housing.
  27. Remove the 2 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
  28. Remove the 10 bolts and the lower intake manifold. Discard the gaskets. 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.
  29. Disconnect and remove the CHT sensor jumper harness.
  30. Remove the valve tappets from the cylinder head. 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.
  31. Remove and discard the M6 bolt.
  32. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket. NOTE: Place clean 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 tighten-to-yield design and cannot be reused.
  33. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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. 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.
  34. 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 «CYLINDER HEAD DISTORTION»(ref-355929-S34550017702010013000000) and «CYLINDER BLOCK DISTORTION»(ref-355929-S07771196582010013000000) .

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.

All vehicles

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Scheme 110
  1. Remove the LH camshafts. For additional information, refer to «Removal and Installation»(ref-355916-S04720268482010060800000) .
  2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  3. Disconnect the A/C compressor electrical connector.
  4. Remove the nut and disconnect the generator B+ cable.
  5. Disconnect the generator electrical connector.
  6. Detach the wiring harness retainer from the generator.
  7. Remove the nut, bolt and the generator.
  8. Detach the wiring harness pin-type retainer.
  9. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
  10. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
  11. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
  12. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
  13. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
  14. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
  15. Remove the 2 LH catalytic converter bracket bolts.
  16. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
  17. Remove the 3 bolts and the LH exhaust manifold heat shield.
  18. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
  19. Clean and inspect the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
  20. Remove and discard the 6 LH exhaust manifold studs.
  21. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block. All-Wheel Drive (AWD) vehicles
  22. Remove the 2 RH catalytic converter bracket bolts. All vehicles
  23. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
  24. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  25. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  26. Disconnect the coolant bypass hose from the thermostat housing.
  27. Remove the 2 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
  28. Remove the 10 bolts and the lower intake manifold. Discard the gaskets. 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.
  29. Remove the bolt and the LH CMP sensor.
  30. Remove the 2 bolts and the upper LH primary timing chain guide.
  31. Remove the 2 bolts and the LH secondary timing chain tensioner.
  32. Remove the valve tappets from the cylinder head. 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.
  33. Remove and discard the M6 bolt.
  34. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket. NOTE: Place clean 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 tighten-to-yield design and cannot be reused.
  35. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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. 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.
  36. 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 «CYLINDER HEAD DISTORTION»(ref-355929-S34550017702010013000000) and «CYLINDER BLOCK DISTORTION»(ref-355929-S07771196582010013000000) .

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, may cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 111

Scheme 111: Removal and Installation
Scheme 111: Removal and Installation

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Scheme 123
  1. Remove the engine from the vehicle. For additional information, refer to «ENGINE»(ref-355916-S04642062192010013000000) .
  2. Remove the 8 bolts and the flywheel.
  3. Remove the crankshaft sensor ring.
  4. Mount the engine on a suitable engine stand. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
  5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
  6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
  7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the Power Steering Pressure (PSP) hose. Remove the block heater wiring harness from the engine.
  8. Disconnect the PCV hose from the PCV valve.
  9. Disconnect the Throttle Body (TB) electrical connector.
  10. Detach the wiring harness retainers from the upper intake manifold.
  11. Remove the upper intake manifold support bracket bolt.
  12. Remove the 6 bolts and the upper intake manifold. Discard the gaskets. 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.
  13. Disconnect the PSP switch electrical connector. Front Wheel Drive (FWD) vehicles
  14. Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector. All vehicles
  15. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
  16. Disconnect the 3 RH coil-on-plug electrical connectors.
  17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  18. Disconnect the LH CMS sensor electrical connector.
  19. Disconnect the LH VCT solenoid electrical connector.
  20. Disconnect the 3 LH coil-on-plug electrical connectors.
  21. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  22. Remove the A/C compressor nut and stud. NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan.
  23. Detach the PSP hose retainer from the engine lifting eye.
  24. Remove the PSP hose bracket nut.
  25. Remove the 3 bolts and position the power steering pump aside.
  26. Remove the 3 bolts and the accessory drive belt tensioner.
  27. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket. FWD vehicles
  28. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket. All vehicles
  29. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  30. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  31. Remove the 6 bolts and the 6 coil-on-plugs. NOTE: LH shown in illustration, RH similar.
  32. Remove the 2 nuts and the wiring harness retaining bracket. Early build vehicles
  33. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
  34. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
  35. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
  36. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
  37. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s). NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
  38. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
  39. Using the 3 Jaw Puller, remove the crankshaft pulley.
  40. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
  41. Remove the 2 bolts and the engine mount bracket.
  42. Remove the 2 engine mount studs. NOTE: Only use hand tools to remove the studs.
  43. Remove the 3 bolts and the engine mount bracket.
  44. Remove the 22 engine front cover bolts.
  45. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence. 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.
  46. Remove the 16 oil pan bolts.
  47. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
  48. Clean the engine front cover and oil pan using a 3M Roloc® 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 and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process. NOTE: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
  49. Clean all engine sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. 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. Make sure the 2 locating dowel pins are seated correctly in the cylinder block. 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, can 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.

All camshafts

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.

Scheme 124

Scheme 124: Removal and Installation
Scheme 124: Removal and Installation

Scheme 125

Scheme 125
Scheme 125

Scheme 126

Scheme 126
Scheme 126
  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage. LH camshafts
  2. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation.
  3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. RH camshafts
  4. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation.
  5. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. All camshafts
  6. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-355916-S30079479932010013000000) . NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage can occur. NOTE: Use a camshaft sprocket bolt to turn the camshafts. LH camshafts
  7. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  8. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
  9. Position the LH secondary timing assembly onto the camshafts.
  10. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  11. Remove the lockpin from the LH secondary timing chain tensioner. RH camshafts
  12. Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
  14. Position the RH secondary timing assembly onto the camshafts.
  15. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
  16. Remove the lockpin from the RH secondary timing chain tensioner. All camshafts
  17. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
  19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
  20. Install the primary timing chain tensioner arm.
  21. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
  22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
  23. As a post-check, verify correct alignment of all timing marks.
  24. Inspect the VCT housing seals for damage and replace as necessary.
  25. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
  26. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
  27. Install the engine front cover. For additional information, refer to «Removal and Installation»(ref-355916-S07935742642010060800000) .

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, may cause engine failure.

Scheme 127

Scheme 127: Removal and Installation
Scheme 127: Removal and Installation
  1. Install the valve tappets. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation.
  2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «Removal and Installation»(ref-355916-S38539097712010060900000) .

More articles — Engine Mechanical - 3.5L