Removal ("B" Bank)
Open the engine compartment hood to service position and install body protection covers. Disconnect the battery ground cable and remove the battery cover. Carefully remove the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
Remove timing cover. See TIMING COVER.
Remove intake manifold. See INTAKE MANIFOLD.
Disconnect the heater hose and temperature sensor connector from the coolant outlet pipe. Loosen and reposition hose clamp along the bypass hose. See Fig. 98.
Remove the 4 bolts which secure the coolant outlet pipe. Remove the coolant outlet pipe from the bypass hose and cylinder head. Remove and discard the sealing rings from the coolant outlet pipe grooves. See Fig. 99.
Remove the nuts which secure the catalytic converter to the "B" bank exhaust manifold flange. See Fig. 26.
Remove the 2 bolts and one nut which secure the Variable Valve Timing (VVT) bushing carrier to the cylinder block. Release the carrier from the 2 ring dowels and remove VVT bushing carrier. See Fig. 138.
Remove the scarf jointed sealing ring from the carrier bushing groove and remove the carrier oil-way recess "O" ring. See Fig. 139.
Raise and support vehicle. Remove the bolt which secures the Crankshaft Position (CKP) sensor to the flywheel housing. Remove the CKP sensor and allow it to hang free under the engine. Remove the torque converter bolts access grommet from the flywheel housing. See Fig. 115.
Install the crankshaft damper bolt (old one) to the crankshaft, hand-tight only. Rotate crankshaft until the triangular arrow indent on the flywheel is visible through the access hole. See Fig. 116. Confirm that the timing flat on each camshaft is uppermost position.
Position the crankshaft so that the Crankshaft Setting Peg (303-531) engages fully into the timing slot. Install and tighten the bolt to secure the crankshaft setting peg. See Fig. 117. Remove the crankshaft damper bolt from the crankshaft and lower the vehicle.
Install the Camshaft Locking Tool (303-530) to the "B" bank camshafts, aligning the shafts slightly as necessary. See Fig. 118.
Loosen the bolts that secure the camshaft sprocket and VVT unit to the camshafts. See Fig. 119. Remove camshaft locking tool.
Remove the primary chain tensioner bolts, primary chain tensioner and tensioner backing plate. See Fig. 120.
Remove the primary timing chain tensioner pivot bolt and remove the primary timing chain tensioner blade. See Fig. 140. Reposition the VVT unit along the cam journal to allow the chain to clear the head casting. Remove the primary timing chain from the VVT unit and secure it to the bypass hose retaining clip, using a tie strap.
Remove the securing bolt from both the VVT unit and the exhaust cam sprocket. Remove the VVT unit, exhaust sprocket and secondary timing chain as an assembly (release the chain from the tensioner which is still secured to the cylinder head). See Fig. 122. Remove the secondary timing chain from the VVT unit and the sprocket.
Remove the 2 bolts which secure the secondary timing chain tensioner to the cylinder head and remove the secondary timing chain tensioner. See Fig. 123.
Remove the bolt which secures the primary timing chain guide. Noting the position of the primary timing chain guide, remove the primary timing chain guide from the upper retaining pin. See Fig. 141.
Remove the camshaft bearing cap bolts. Loosen the camshaft bearing caps evenly, in stages. Remove the camshaft bearing caps, noting their position and markings (each is marked with its numbered position and orientation arrow). Remove the camshafts from the engine. See Fig. 125.
Noting the position of each tappet for reassembly, remove each tappet and shim assembly (retain each shim with its original tappet). Mark the inside face of each tappet in pencil or felt tipped pen, with its original position within the cylinder head. See Fig. 126.
Disconnect the engine position sensor connector, at the rear of the cylinder head. See Fig. 142.
Place a drain tray under the engine. Using a syringe with a length of thin rubber line connected, drain the residual coolant from the outlet pipe water-way. See Fig. 127. A suitable syringe is Snap On YA 745.
Place a cloth around the area of the cylinder head to absorb coolant spillage when removing the head. Remove the cylinder head bolts. Remove the cylinder head. See Fig. 128.
Noting how the cylinder head gasket is fitted, remove the cylinder head gasket. Remove and discard absorbent cloth. See Fig. 129. Remove the coolant drain tray from under the engine. Remove and discard the gasket from the downpipe catalyst.
Clean the gasket faces of the catalyst and the exhaust manifold. Clean cylinder head and cylinder block gasket faces. Ensure that all threaded holes in the cylinder block face are clean and free from oil. Clean and inspect the cylinder head bolts. Cylinder head bolts may be re-used on 2 occasions. When re-used, each bolt head should be marked with one dot from an automatic center punch. Clean and inspect all relevant components and mating faces.
Installation
Install a NEW gasket to the downpipe catalyst flange.
Install and align a NEW cylinder head gasket to the cylinder block face. See Fig. 129.
Install the cylinder head. Engage cylinder head with the dowels on the block face, and exhaust manifold flange with the studs on the downpipe catalyst. See Fig. 128. Install cylinder head bolts hand tight.
Tighten cylinder head bolts in sequence to proper specification. See TORQUE SPECIFICATIONS. See Fig. 130. Center punch bolts after torque sequence is complete.
Connect the engine position sensor connector at the rear of the cylinder head. See Fig. 142.
Lubricate each tappet assembly. Install each tappet and shim assembly to its previously noted position in the cylinder head. See Fig. 126.
Apply oil (EP-90) to the camshaft and bearing surfaces as follows:
Upper face of each bearing surface (2 places) in the cylinder head.
Upper face of each bearing surface (2 places) in each bearing cap.
On the cam lobes ONLY, not on the base circle area.
See Fig. 131.
Install the camshafts in the cylinder head with the timing flats in the uppermost position. Install the camshaft bearing caps to their respective locations (inlet 0 to 4 and exhaust 5 to 9 from the front) and in the correct orientation (arrow to front of engine). Install and tighten the bearing cap bolts evenly and in stages to specification. See TORQUE SPECIFICATIONS. Install the camshaft locking tool and align camshafts as necessary.
NOTE:The primary timing chain guide must be installed so that the slotted hole is towards the top, and the raised shoulder to the cylinder block.
Install the primary timing chain guide to the block and locate it onto the upper retaining pin. See Fig. 141. Install the retaining bolt and tighten specification. See TORQUE SPECIFICATIONS.
Push the secondary timing chain tensioner piston into the tensioner body to provide clearance for installing the secondary timing chain. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. See Fig. 132. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
Install the secondary timing chain tensioner to the engine. Fully seat the secondary timing chain tensioner to the cylinder head. See Fig. 123. Install the 2 secondary timing chain tensioner bolts and tighten to specification. See TORQUE SPECIFICATIONS.
Assemble the VVT unit, the exhaust camshaft sprocket and the secondary timing chain. Install the assembly to the camshafts with the secondary timing chain correctly positioned over the secondary timing chain tensioner. Fit the VVT unit to the inlet camshaft and the sprocket to the exhaust camshaft. Install, but do not tighten, each bolt which secures the VVT unit and the exhaust sprocket to the camshafts. See Fig. 122.
Install the Chain Tensioning Tool (303-532) to the exhaust camshaft sprocket. Reposition the sprocket (and the VVT unit) for the most advantageous position for use of the tool. See Fig. 143. Remove the tool.
Install the primary timing chain. Reposition the VVT unit forwards on the cam journal (do not rotate it) to allow the primary timing chain to clear the head casting. Remove the primary timing chain from the tie strap. Install the primary timing chain into position over the crankshaft sprocket and the VVT unit sprocket. There must be no slack on the drive side of the primary timing chain and the VVT unit must not be rotated on the camshaft. See Fig. 144.
Install the primary timing chain tensioner blade to the cylinder block. See Fig. 140. Install the pivot bolt and tighten specification. See TORQUE SPECIFICATIONS.
Push the primary timing chain tensioner piston into the tensioner body to provide clearance for installing the primary timing chain. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. See Fig. 135. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
Install the 2 primary timing chain tensioner bolts to the primary timing chain tensioner and locate the tensioner backing-plate on to the 2 bolts. Align and install the primary timing chain tensioner to the cylinder block and to the mating slot on the rear face of the primary timing chain tensioner blade. See Fig. 120. Tighten the primary timing chain tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Use a Primary Chain Wedge (303-533), or 2 if needed, between the primary timing chain tensioner and primary timing chain tensioner blade, to take up the slack in the chain for tightening of the VVT unit and exhaust camshaft sprocket. See Fig. 136.
Install the chain tensioner tool to the sprocket holes. See Fig. 145. Apply force to the tool in an counterclockwise direction to tension the chain on its drive side. While applying opposing force to the sprocket and chain, tighten the camshaft sprocket bolt to specification. Check that the primary chain wedges are still in place. While still applying opposing force to the sprocket and chain with the chain tensioner tool, tighten the VVT unit bolt to specification. See TORQUE SPECIFICATIONS. Remove the chain tensioning tool, primary chain wedges and camshaft locking tool.
Raise and support vehicle. Remove crankshaft setting peg. Install the CKP sensor and bolt to the flywheel housing. See Fig. 115. Tighten the CKP sensor bolt to specification. See TORQUE SPECIFICATIONS. Install the access grommet to the housing and lower the vehicle.
Install and tighten the nuts which secure the catalytic converter to the "B" bank exhaust manifold flange. See Fig. 26.
Install a NEW scarf jointed sealing ring to the carrier bushing groove and a NEW carrier oil-way recess "O" ring. See Fig. 139.
Lubricate the scarf jointed sealing ring, the carrier oil-way recess "O" ring and the bushing. Install the bushing carrier assembly, ensuring that the seals are in place and that the ring dowels are engaged squarely. Fully locate the assembly as much as possible by hand. Install the 2 securing bolts and one nut and tighten to specification. See TORQUE SPECIFICATIONS. See Fig. 138.
Install NEW sealing rings to the coolant outlet pipe grooves. Install the outlet pipe to the bypass hose and cylinder heads. See Fig. 99. Install the 4 coolant outlet pipe bolts and tighten to specification. See TORQUE SPECIFICATIONS.
Connect the heater hose and reposition the hose clamp to secure the heater hose. Connect the temperature sensor connector. Reposition the bypass hose clamp to secure the bypass hose. See Fig. 98.
Install the inlet manifold. This operation includes installing the throttle housing. See INTAKE MANIFOLD.
Install the timing cover. See TIMING COVER.
Connect battery. See BATTERY RECONNECT PROCEDURE under MISCELLANEOUS.
Carefully install the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
Refill cooling system. See COOLING SYSTEM.
Check for leaks and that all coolant hoses are securely connected. Move the engine compartment hood from the service position and connect the gas struts. Remove the body protection covers and close the engine compartment.
Wednesday, March 22nd, 2017 AT 4:25 PM
(Merged)
