Special tool
 Valve timing tool 303-645 |  Camshaft Installer/Lock Tool 303-530 |  Crankshaft oil seal mounting tool adapter 303-1100-01 |
 Adapter 303-191-03 |  Crankshaft pulley locking tool 303-893 (LRT-12-080) |  Bolts and spacers 303-191-04 |
 Tool for tensioning the timing chain 303-532 |
Disassembly
1. Remove the engine assembly. For more information refer to Engine (12.41.01.99)
2. Fix the engine on the engine stand.
- Adjust the position of the engine on the engine stand.
- Adjust the position of the motor stand legs.
- Install the engine on a motor stand.
- Fully tighten the motor stand leg nuts.
4. Remove the coolant manifold.
- Turn out 4 bolts.
- Disconnect the electrical connector.
5. Move the wiring harness support bracket out of the way for access. Turn out 2 bolts.
6.
NOTE: The illustration shows the right side, the left side is the same.
Remove both direct ignition coil covers. Release from 2 clips.
7.
NOTE: The illustration shows the right side, the left side is the same.
Disconnect the electrical connectors of the 8 direct ignition coils (coils in a block with spark plugs).
8. Remove 8 direct ignition coils. Remove 8 bolts.
9. Disconnect the ventilation hose from the cylinder head cover.
- Disconnect the variable valve timing oil control solenoid valve electrical connector (VCT).
- Repeat the operation on the other side.
10. Disconnect the electrical connector of the engine coolant temperature sensor (ECT).
11. Disconnect the CMP sensor electrical connector. Repeat the above procedure on the right side.
12. Disunite an electric socket of weight of a head of cylinders.
- Turn out a bolt.
- Release 3 clamps.
13. Disconnect the electrical connector of the knock sensors (KS).
14. Disconnect the purge valve from the support bracket.
- Disconnect the quick coupling.
- Disconnect the electrical connector.
- Turn out a bolt.
15. Release the 5 clamps on the A/C harness.
16. Remove the crankshaft position sensor (TFR).
- Disconnect the electrical connector.
- Remove the Torx head screw.
17. Remove the power steering pump support bracket.
- Turn out 3 bolts.
- Loosen the transmission fluid cooler line clamps.
18. Remove the A/C compressor support bracket. Turn out 2 bolts.
19. Disunite an electric socket of a starter.
20. Disconnect the engine oil temperature and pressure sensors.
21. Disunite an electric socket of the generator.
22. Release 4 clips of fastening of a plait of electroconducting of the generator.
23. Turn out 10 bolts of an inlet collector.
24.
CAUTION: Before disconnecting or removing components, clean the area around the contact surfaces and connections. Plug all open connections to avoid contamination of the system.
Remove the intake manifold.
- Disconnect the brake booster vacuum hose from the intake manifold.
- Discard the gaskets.
- Disconnect the intake manifold absolute pressure sensor electrical connector (MAP).
25. Remove the auxiliary drive belt idler pulley. Turn out a bolt.
26. Remove the coolant pump pulley. Turn out 3 bolts.
27. Remove the coolant pump.
28. Remove the generator.
- Disconnect the electrical connector.
- Turn out 3 bolts.
29. Remove the generator support bracket. Turn out 4 bolts.
30. Remove the dipstick and oil level indicator tube
- Loosen the nut.
- Discard the O-ring.
31. Remove the right cylinder head cover.
- Turn out 14 bolts of fastening of a cover of a head of cylinders.
- Remove and discard the cylinder head cover gasket.
- Remove the seals from the spark plug holes in the cylinder head cover and discard them.
- Repeat the operation on the left side.
32. Remove the engine front cover.
- Release the engine wiring harness clamps.
- Remove 24 bolts.
- Remove the gasket and discard it.
33. Rotate the crankshaft until the flats on the camshafts are parallel to the mating surfaces of the cylinder head.
34.
NOTE: The engine is now in the SAFE position.
Block the crankshaft.
- Install the special tool.
- Screw in the screw.
35. Remove the right VCT control unit.
- Turn out 3 bolts.
- Remove the o-rings and discard them.
36. Install the special tool on the right cylinder head. Screw in 3 bolts.
37. Remove the right primary timing chain tensioner. Turn out 2 bolts.
38. Remove the right primary timing chain tensioner guide. Turn out a bolt.
39. Remove the right primary timing chain.
40. Remove the left VCT control box.
- Turn out 2 bolts.
- Loosen the nut.
- Remove the o-rings and discard them.
41. Install the special tool on the left cylinder head. Screw in 3 bolts.
42. Remove the left primary timing chain tensioner. Turn out 2 bolts.
43. Remove the upper and lower guides of the left primary timing chain tensioner.
- Unscrew the pin.
- Turn out a bolt.
44. Remove the left primary timing chain.
45.
CAUTION: Discard bolts.
Remove the camshaft sprockets. Turn out 2 bolts.
46. Remove the secondary timing chain tensioner and secondary timing chain. Turn out 2 bolts.
47. Remove the special tool from the left cylinder head. Turn out 3 bolts.
48.
CAUTION: Loosen the camshaft bearing caps evenly and gradually.
NOTE: Remove the camshaft bearing caps. Note: note their position, direction and markings. Each lid is marked with its position (number) and directions (arrow).
Remove the camshaft bearing caps. Remove 20 bolts.
49. Remove camshafts.
50. Install the special tool on the right cylinder head. Screw in 3 bolts.
51.
CAUTION: Discard bolts.
NOTE: left side shown, right side similar.
Remove the camshaft sprockets. Turn out 2 bolts.
52.
NOTE: Left side shown, right side similar.
Remove the secondary timing chain tensioner and secondary timing chain. Turn out 2 bolts.
53.
CAUTION: Loosen the camshaft bearing caps evenly and gradually.
NOTE: Remove the camshaft bearing caps. Note: note their position, direction and markings. Each lid is marked with its position (number) and directions (arrow).
NOTE: Left side shown, right side similar.
Remove the camshaft bearing caps. Remove 20 bolts.
54.
WARNING: Bolts can be reused twice. Mark the bolts to be reused by marking them with a center punch. If the bolts have two punched points, discard the bolts.
Remove the left row cylinder head assembly.
- Remove 12 cylinder head bolts.
- With the help of another mechanic, remove the cylinder head.
- Remove the cylinder head gasket and discard it.
- Clean the dowel pins of the cylinder head.
- Clean the mating surfaces of the elements.
- Repeat the operation on the right side.
55. Turn out 4 bolts of fastening of an arm of a support of the engine to the block of cylinders.
56.
CAUTION: Mark the location of the bolt.
Remove the starter. Remove the remaining starter bolt.
57. Remove KS.
58. Remove the faceplate. Remove and discard 8 bolts.
59.
NOTE: There may be some differences from the pictures shown, but the basic information is correct.
Remove the oil pan.
- Remove 18 bolts.
- Thoroughly clean all mating surfaces and reusable parts and inspect them for damage.
60. Remove the oil receiver intake tube with strainer assembly.
- Turn out 2 bolts.
- Remove and discard the O-ring.
61. Remove the reflective plate. Turn out 6 bolts.
62. Remove the oil pump assembly.
- Turn out 4 bolts.
- Remove the gasket and discard it.
- Clean the mating surfaces of the elements.
63. Remove the engine from the motor stand. With the help of a second mechanic, remove the engine block from the stand.
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