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Crankshaft Pulley Replacement > < Turbocharger Wastegate Actuator Pipe Replacement - with Start/Stop System

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Camshaft Housing Cover Gasket Replacement (with Start/Stop System)

Special Tools

•  GE-328-B   Sliding Hammer
•  EN-955-1   Locking Tool
•  EN-48559   Protective Caps
•  EN-46781   Fixing Tool
•  EN-46786   Remover
•  EN-47632   Cleaning Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

1. Open the hood.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the air cleaner housing. Refer to Air Cleaner Replacement .
4. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

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Note:  Use a small screwdriver to unclip the retainer clip (black arrow) and pull the electronic control module out.
5. Remove the electronic control module (1) from the battery tray.

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6. Remove the 2 charge air cooler outlet air hose bolts (3).
7. Remove the charge air cooler outlet air hose bolt from the radiator inlet hose bracket.
8. Remove the charge air cooler outlet air hose (4) from the throttle body (1) and hang aside.
9. Remove the charge air cooler outlet air hose seal (2).

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10. Disconnect the positive crankcase ventilation pipe connector (3) from the positive crankcase ventilation oil separator.
11. Disconnect the positive crankcase ventilation pipe connector wiring harness plug.
12. Remove the vacuum hose from the turbocharger wastegate actuator vacuum control solenoid valve.
13. Remove the 2 positive crankcase ventilation pipe bracket bolts (2).
14. Remove the positive crankcase ventilation pipe (1).

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15. Unclip the oxygen sensor plug from the exhaust pressure sensor bracket and the ECM wiring harness.
16. Remove the oxygen sensor (1) from the catalytic converter (2).

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17. Disconnect the air conditioning compressor wiring harness plug (3).
18. Disconnect the exhaust temperature sensor wiring harness plug (5).
19. Unclip the retainer clip (4) from the exhaust temperature sensor wiring harness bracket.
20. Disconnect the turbocharger wastegate sensor wiring harness plug (2).
21. Unclip the retainer clip (6) from the oil filter housing.
22. Disconnect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug (1).
23. Unclip the retainer clip from the turbocharger wastegate actuator vacuum control solenoid valve bracket.

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24. Disconnect the camshaft sensor wiring harness plug (1) from the camshaft sensor (3).
25. Unclip the 3 retainer clips from:
  •  Engine lift bracket (5)
  •  Engine sight shield stud bracket (4)
  •  Oil filler tube (2)

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26. Disconnect the 4 fuel injector wiring harness plugs (8).
27. Disconnect the fuel rail sensor wiring harness plug (1).
28. Disconnect the manifold absolute pressure sensor wiring harness plug (2).
29. Disconnect the oxygen sensor wiring harness plug (3).
30. Disconnect the exhaust pressure sensor wiring harness plug (4).
31. Disconnect the throttle body wiring harness plug (5).
32. Remove the 2 wiring harness bracket bolts (6).
33. Unclip the ECM wiring harness from the radiator inlet hose bracket.
34. Disconnect the glow plug wiring harness connector (7).
35. Disconnect the engine coolant temperature sensor wiring harness plug from the thermostat housing.
36. Disconnect the oil temperature sensor wiring harness plug from the oil temperature sensor.
37. Disconnect the crankshaft position sensor wiring harness plug from the crankshaft position sensor.
38. Disconnect the fuel injection fuel pump wiring harness plug from the fuel injection fuel pump.
39. Disconnect the backup lamp switch wiring harness plug from the backup lamp switch.
40. Unclip the wiring harness retainer clips.
41. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
42. If equipped, remove the engine shield. Refer to Engine Shield Replacement .
43. If equipped, remove the front the compartment splash shield. Refer to Front Compartment Splash Shield Replacement .

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44. Unclip the generator wiring harness clip from the exhaust gas recirculation valve vacuum tank (2).
45. Remove the turbocharger wastegate actuator hose (1).
46. Remove the turbocharger wastegate actuator pipe (4).
47. Remove the 2 exhaust gas recirculation valve vacuum tank bolts (3).
48. Remove the exhaust gas recirculation valve vacuum tank (2).

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49. Disconnect the generator wiring harness plug (2).
50. Disconnect the exhaust gas recirculation valve wiring harness plug (1).
51. Disconnect the exhaust gas recirculation cooler wiring harness plug (4).
52. Remove the starter control cable nut.
53. Remove the starter control cable (3).
54. Unclip the wiring harness from the oil level indicator tube.
55. Unclip the wiring harness from exhaust gas recirculation cooler.
56. Lower the vehicle.
57. Hang the ECM wiring harness aside.

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58. Remove the fuel feed pipe (1) from the fuel injection pump (4).
  Disconnect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
59. Remove the fuel return pipe (2) from the fuel separator (3).
  Disconnect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .

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60. Remove the brake booster vacuum pipe (2) from the vacuum pump (1).
  Disconnect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
61. Remove the turbocharger wastegate actuator vacuum hose from the vacuum pump.

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62. Remove the fuel feed pipe (2) from the fuel injection fuel pump (3) and the fuel rail (1).
  •  Remove the fuel feed pipe nut from the fuel rail.
  •  Remove the fuel feed pipe nut from the fuel injection fuel pump.

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63. Unclip the 4 fuel injector fuel return hose retainer springs (6).
64. Remove the fuel injector fuel return hose (1) from the 4 fuel injectors.
65. Remove the fuel return hose clamp (5).
66. Remove the fuel return hose (2) from the fuel injector pump.
67. Remove the fuel separator bolt (4).
68. Remove the fuel injector fuel return hose with the fuel separator (3).

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69. Loosen the 2 fuel rail bolts.
70. Remove the 4 fuel feed pipes (1) from the 4 fuel injectors (3) and the fuel rail (2).
  •  Remove the 4 fuel feed pipe nut from the fuel rail.
  •  Remove the 4 fuel feed pipe nut from the 4 fuel injectors.

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71. Remove the 3 fuel rail bracket bolts (1).
72. Remove the engine lift bracket (2).
73. Remove the fuel rail (3) with the fuel rail bracket (4).

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74. Remove the 2 fuel injector bracket nuts (2).
75. Remove the 2 fuel injector conical washer (3).
76. Remove the 2 fuel injector spherical washers (4).

Note:  Injectors are to be removed only in pairs. If the Injectors are not removed by hand use the EN-46786   remover with GE-328-B   sliding hammer .
77. Remove the 4 fuel injectors (1) with the 2 fuel injector brackets (7).
78. Remove the 4 fuel injector seals (5).
79. Close the injector nozzles with the EN-48559   protective caps .

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80. Remove the 2 glow plug wiring harness bracket bolts (2).
81. Remove the glow plug wiring harness bracket (1).

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82. Remove the engine control module wiring harness bracket bolt (2).
83. Remove the engine control module wiring harness bracket (1) left side.

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84. Remove the 2 engine control module wiring harness bracket bolts (2).
85. Remove the engine control module wiring harness bracket (1) right side.

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86. Remove the 2 oil filler tube bolts (2, 3).
87. Remove the oil filler tube (1) from the oil pump housing (4).

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
88. Assemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
89. Support the CH-904   base frame on a jack.
90. Support the CH-49290   engine support tool on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
91. Install the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
92. Lower the vehicle.

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93. Remove the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4).
94. Remove the 2 engine mount to body bolts (2) and the engine mount nut (1).
95. Remove the engine mount (5).

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96. Remove 4 engine mount bracket bolts (3).
97. Remove engine lift bracket (2).
98. Remove engine mount bracket (1).

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99. Remove the intake camshaft housing core hole plug (1) from the camshaft housing.
100. Clean the threads at the camshaft housing and the camshaft housing core hole plug.

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101. Mark (arrow) at the EN-46781   fixing tool (1).

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Note:  The EN-46781   fixing tool (1) must be installed in horizontal position.
102. Install the EN-46781   fixing tool (1) into the intake side.

Note:  If the EN-46781   fixing tool does not rotate any longer, the tool is correctly engaged.
103. Turn the crankshaft at the crankshaft sprocket bolt carefully, until the EN-46781   fixing tool (1) engages at the intake camshaft.
104. Raise the vehicle.

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Note:  Turn the crankshaft carefully until EN-46785   fixing tool engages in the flywheel.
105. Install the EN-46785   fixing tool (1).
106. Lower the vehicle.

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107. Remove the oil pump housing plug (1) from the oil pump housing (3).
108. Remove the oil pump housing plug seal (2).

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109. Remove the 4 oil pump housing closure cover bolts (4).
110. Remove the oil pump housing closure cover (1) from the oil pump housing (3).
111. Remove the oil pump housing closure cover gasket (2).

Note:  Do NOT remove the camshaft sprocket bolt.
112. Loosen the camshaft sprocket bolt.

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113. Tension the timing chain tensioner (1).
114. Fixing the timing chain tensioner position with the EN-955-1   locking tool (2).

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115. Remove the camshaft sprocket bolt.
116. Remove the camshaft sprocket from the exhaust camshaft. Using a bent piece of rigid wire (1).

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117. Remove the 5 oil pump housing bolts from the oil pump housing (2) and camshaft housing.

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Note:  Take note that there are different bolt lengths.
118. Remove the 16 camshaft housing bolts (2).
119. Remove the 2 camshaft housing studs (1).

Note:  Carefully lever the camshaft housing off timing case gasket with plastic wedge and use a rubber mallet to knock it off the timing case. Place the camshaft housing on suitable support.
120. Remove the camshaft housing (3).
121. Remove the camshaft housing gasket (4).

Installation Procedure


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1. Remove the upper oil pump housing gasket.
  •  Cut into the elastomer sealing lips (arrows) using a sharp knife pressed against the cylinder head.
  •  With a plastic spatula, loosen the seal from the timing case and carefully snap it off at the designated point (1).
  •  Remove the upper oil pump housing gasket.

Note:  Make sure that no residues remain at the joint between the timing case and cylinder head, and that no bits of the gasket fall into the timing case.
2. Remove any gasket residue and clean all sealing surfaces thoroughly.

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3. Fit the NEW oil pump housing gasket. (1).
  Using a sharp knife, cut into the elastomer sealing lips (arrows) at the breaking points of the new gasket.

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Note:  It is essential for the cutting tool (1) to have a straight cutting surface.
4. Cut the NEW oil pump housing gasket off at the breaking points (arrow).

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Note:  The upper new gasket and the old lower gasket must not be allowed to overlap.
5. Fit NEW oil pump housing gasket (1) to the contact surface between the cylinder block and the timing case until the seal lies flush on the cylinder head and timing case (arrows) and the holes in the gasket and the timing case match up.
6. Clean any oil and grease of the exhaust camshaft, camshaft sprocket, camshaft sprocket bolt and thread in exhaust camshaft.

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7. Clean all sealing surfaces.
8. Apply silicone sealing compound to the transitions between the cylinder head and oil pump housing (1).
9. Install NEW camshaft housing gasket.
10. Apply silicone sealing compound to the transitions between the camshaft housing gasket and oil pump housing.

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11. Install the camshaft housing (3).

Note:  Tightening the 2 camshaft housing studs in sequence until the camshaft housing is lying evenly on the cylinder head.
12. Loosely install the 2 camshaft housing studs (1).

Note:  Mind at different bolt length.
13. Loosely install the 16 camshaft housing bolts (2).
14. Carefully align the camshaft housing on the oil pump housing, using a rubber mallet.

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15. Install the 5 oil pump housing bolts (1) to the oil pump housing (2) and camshaft housing and tighten the bolts carefully until the camshaft housing is in contact with the oil pump housing.

Caution: Refer to Fastener Caution .

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16. Tighten the 16 camshaft cover bolts and the 2 camshaft cover studs in sequence as shown and first step:
  •  For camshaft housing bolts M7 to 12 N·m (106 lb in) .
  •  For camshaft housing studs M8 to 15 N·m (11 lb ft) .
17. Tighten the 16 camshaft cover bolts and the 2 camshaft cover studs in sequence as shown and final step:
  •  For camshaft housing bolts M7 to 18 N·m (13 lb ft) .
  •  For camshaft housing studs M8 to 25 N·m (18 lb ft) .

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18. Tighten the 5 oil pump housing bolts (13 - 17) in sequence as shown:
  •  In first step and in sequence as shown, tighten to 4 N·m (35 lb in) .
  •  In second step and in sequence as shown, tighten to 9 N·m (80 lb in) .

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19. Install the camshaft sprocket to the exhaust camshaft.
  •  Using a suitable tool (1), place the drive gear on the exhaust camshaft.
  •  Loosely install camshaft sprocket bolt.

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20. Remove the EN-955-1   locking tool (2) from timing chain tensioner (1).

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Note:  A second mechanical must tighten the timing chain tensioner (1) with a suitable tool (2) while the timing chain is being tightened.
21. Tighten the camshaft sprocket bolt to 150 N·m (111 lb ft) .

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22. Remove the EN-46785   fixing tool (1).

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23. Remove the EN-46781   fixing tool (1).
24. Turn the crankshaft 720° (2 turns) in the direction of engine rotation.
25. Check the camshaft timing. Refer to Camshaft Timing Chain Inspection .

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26. Install the oil pump housing closure cover gasket (2).
27. Install the oil pump housing closure cover (1) to the oil pump housing (3).
28. Install the 4 oil pump housing closure cover bolts (4) and tighten to 9 N·m (80 lb in) .

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29. Install the oil pump housing plug seal (2).
30. Install the oil pump housing plug (1) to the oil pump housing (3) and tighten to 9 N·m (80 lb in) .

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31. Install the intake camshaft housing core hole plug (1) to the camshaft housing and tighten to 15 N·m (11 lb ft) .

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32. Install the engine mount bracket (1).
33. Install the engine lift bracket (2).
34. Install the 4 engine mount bracket bolts (3) and tighten to 60 N·m (44 lb ft) .

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35. Install the engine mount (5).
36. Install the 2 engine mount to body bolts (2) and the engine mount nut (1) and tighten to 62 N·m (46 lb ft) .
37. Install the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4) and tighten to 62 N·m (46 lb ft) .
38. Raise the vehicle.

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39. Lower the CH-49290   engine support tool (1).
40. Remove the CH-49290   engine support tool from CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
41. Disassemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.

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42. Install the oil filler tube (1) to oil pump housing (4).
43. Install the 2 oil filler tube bolts (2, 3) and tighten to 9 N·m (80 lb in) .

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44. Install the engine control module wiring harness bracket (1) right side.
45. Install the 2 engine control module wiring harness bracket bolts (2) and tighten to 9 N·m (80 lb in) .

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46. Install the engine control module wiring harness bracket (1) left side.
47. Install the engine control module wiring harness bracket bolt (2) and tighten to 9 N·m (80 lb in) .

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48. Install the glow plug wiring harness bracket (1).
49. Install the 2 glow plug wiring harness bracket bolts (2) and tighten to 9 N·m (80 lb in) .

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50. Clean the injector sealing surfaces in the cylinder head using EN-47632   cleaning tool (1) in following procedure:
  •  First take the brush side to loosen the dirt.
  •  Second take the sponge side to remove the dirt.

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51. Install the 4 NEW fuel injector gaskets (6) to the camshaft housing.
52. Remove the EN-48559   protective caps from the injector nozzles.
53. Install the 4 NEW fuel injector seals (5) to the fuel injectors.
54. Install the 4 fuel injectors (1) with the 2 fuel injector brackets (7).
55. Install the 2 fuel injector spherical washers (4).
56. Install the 2 fuel injector conical washer (3).
57. Install the 2 fuel injector bracket nuts (2) and tighten to 20 N·m (15 lb ft) .

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58. Install the fuel rail (3) with the fuel rail bracket (4).
59. Install the engine lift bracket (2).
60. Install the 3 fuel rail bracket bolts (1) and tighten to 25 N·m (18 lb ft) .

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61. Install the 4 fuel injection fuel feed pipes (1).
62. Install the 4 fuel injection fuel feed pipe nut M12 to 4 fuel injectors (3) and tighten to 24 N·m (18 lb ft) .
63. Install the 4 fuel injection fuel feed pipe nuts M14 to fuel rail (2) and tighten to 28 N·m (21 lb ft) .
64. Tighten the 2 fuel rail bolts to 25 N·m (18 lb ft) .

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65. Install the fuel injector fuel return hose with the fuel separator (3).
66. Install the fuel separator bolt (4) and tighten to 9 N·m (80 lb in) .
67. Install the fuel return hose (2) to the fuel injector pump.
68. Install the fuel return hose clamp (5).
69. Install the fuel injector fuel return hose (1) to the 4 fuel injectors.
70. Clip in the 4 fuel injector fuel return hose retainer springs (6).

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71. Install the fuel feed pipe (2) to the fuel injection fuel pump (3) and the fuel rail (1).
  •  Install fuel feed pipe nut M12 to fuel injection fuel pump and tighten to 24 N·m (18 lb ft) .
  •  Install fuel feed pipe nut M14 to fuel rail and tighten to 28 N·m (21 lb ft) .
72. Install the turbocharger wastegate actuator vacuum hose to the vacuum pump.

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73. Install the brake booster vacuum pipe (2) to the vacuum pump (1).
  Connect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .

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74. Install the fuel feed pipe (1) to the fuel injection pump (4).
  Connect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
75. Install the fuel return pipe (2) to the fuel separator (3).
  Connect the plastic collar quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
76. Position the ECM wiring harness.
77. Raise the vehicle.

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78. Clip in the wiring harness to exhaust gas recirculation cooler.
79. Clip in the wiring harness to oil level indicator tube.
80. Install the starter control cable (3).
81. Install the starter control cable nut and tighten to 13 N·m (115 lb in) .
82. Connect the exhaust gas recirculation cooler wiring harness plug (4).
83. Connect the exhaust gas recirculation valve wiring harness plug (1).
84. Connect the generator wiring harness plug (2).

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85. Install the exhaust gas recirculation valve vacuum tank (2).
86. Install the 2 exhaust gas recirculation valve vacuum tank bolts (3) and tighten to 22 N·m (16 lb ft) .
87. Install the turbocharger wastegate actuator pipe (4).
88. Install the turbocharger wastegate actuator hose (1).
89. Clip in the generator wiring harness clip to the exhaust gas recirculation valve vacuum tank (2).
90. If equipped, install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
91. If equipped, install the engine shield. Refer to Engine Shield Replacement .
92. Lower the vehicle.
93. Clip in the wiring harness retainer clips.
94. Connect the backup lamp switch wiring harness plug to the backup lamp switch.
95. Connect the fuel injection fuel pump wiring harness plug to the fuel injection fuel pump.
96. Connect the crankshaft position sensor wiring harness plug to the crankshaft position sensor.
97. Connect the oil temperature sensor wiring harness plug to the oil temperature sensor.
98. Connect the engine coolant temperature sensor wiring harness plug to the thermostat housing.

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99. Connect the glow plug wiring harness connector (7).
100. Clip in the ECM wiring harness to the radiator inlet hose bracket.
101. Install the 2 wiring harness bracket bolts (6) and tighten to 9 N·m (80 lb in) .
102. Connect the throttle body wiring harness plug (5).
103. Connect the exhaust pressure sensor wiring harness plug (4).
104. Connect the oxygen sensor wiring harness plug (3).
105. Connect the manifold absolute pressure sensor wiring harness plug (2).
106. Connect the fuel rail sensor wiring harness plug (1).
107. Connect the 4 fuel injector wiring harness plugs (8).

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108. Connect the camshaft sensor wiring harness plug (1) to the camshaft sensor (3).
109. Clip in the 3 retainer clips to:
  •  Engine lift bracket (5)
  •  Engine sight shield stud bracket (4)
  •  Oil filler tube (2)
110. Clip in the retainer clip to the turbocharger wastegate actuator vacuum control solenoid valve bracket.

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111. Connect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug (1).
112. Clip in the retainer clip (6) to the oil filter housing.
113. Connect the turbocharger wastegate sensor wiring harness plug (2).
114. Clip in the retainer clip (4) to the exhaust temperature sensor wiring harness bracket.
115. Connect the exhaust temperature sensor wiring harness plug (5).
116. Connect the air conditioning compressor wiring harness plug (3).

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117. Install the oxygen sensor (1) to catalytic converter (2) and tighten to 45 N·m (33 lb ft) .
118. Clip in the oxygen sensor plug to exhaust pressure sensor bracket and ECM wiring harness.

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119. Install the positive crankcase ventilation pipe (1).
120. Install the 2 positive crankcase ventilation pipe bracket bolts (2) and tighten to 8 N·m (71 lb in) .
121. Install the vacuum hose to turbocharger wastegate actuator vacuum control solenoid valve.
122. Connect the positive crankcase ventilation pipe connector wiring harness plug.
123. Connect the positive crankcase ventilation pipe connector (3) to the positive crankcase ventilation oil separator.

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124. Install the charge air cooler outlet air hose seal (2).
125. Install the charge air cooler outlet air hose (4) to the throttle body (1).
126. Install the air cooler outlet air hose bolt to the radiator inlet hose bracket and tighten to 10 N·m (89 lb in) .
127. Install the 2 charge air cooler outlet air hose bolts (3) and tighten to 10 N·m (89 lb in) .

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128. Install the electronic control module (1) to the battery tray.
129. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
130. Install the air cleaner housing. Refer to Air Cleaner Replacement .
131. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
132. Close the hood.

Crankshaft Pulley Replacement > < Turbocharger Wastegate Actuator Pipe Replacement - with Start/Stop System