Removal and Replacement
Cylinder Head
RH Splash Shield
RH Splash Shield:
Accessory Drive Belt, Thermostat Housing and Fuel Rail
Accessory Drive Belt, Thermostat Housing and Fuel Rail:
RH Accessory Drive and Timing Drive Components
RH Accessory Drive and Timing Drive Components (Part 1):
RH Accessory Drive and Timing Drive Components (Part 2):
LH Accessory Drive and Timing Drive Components
LH Accessory Drive and Timing Drive Components (Part 1):
LH Accessory Drive and Timing Drive Components (Part 2):
LH Spark Plug Wires, Oil Level Indicator and Tube and Ground Strap
LH Spark Plug Wires, Oil Level Indicator and Tube and Ground Strap (Part 1):
LH Spark Plug Wires, Oil Level Indicator and Tube and Ground Strap (Part 2):
Removal
Both sides
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine cooling system.
3. Remove the intake manifold.
4. Remove the cooling fan shroud.
5. Remove the roller followers.
6. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.
7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
8. NOTE: The coolant bypass hose will be removed with the thermostat housing.
Move the coolant bypass hose clamp off the coolant pump outlet.
9. Remove the bolts and the thermostat housing and coolant bypass hose.
10. Remove the bolts and the fuel rail and fuel injector assembly.
11. Remove the nut and position the A/C hose bracket aside.
12. NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the No. piston at top dead center (TDC).
RH side
13. Disconnect the generator electrical connections.
14. Remove the bolt and the accessory drive belt tensioner.
15. Remove the bolts and the generator bracket assembly.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Detach the wiring harness retainers and position the wiring harness aside.
^ Remove and discard the retainers.
18. Remove the RH inner fender splash shield.
19. Remove the RH hydraulic chain tensioner.
20. Remove the RH exhaust manifold.
21. Remove bolt and position the wiring harness bracket aside.
22. Install the special tools.
^ Tighten to 10 Nm (89 lb-inch).
23. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.
24. Remove the RH timing drive cassette upper bolt.
25. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
LH side
26. Remove the bolts and position the power steering and A/C compressor bracket aside.
27. Remove the bolt and detach the wiring harness from the LH cylinder head.
28. Remove the bolt and the oil level indicator tube.
29. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct spark plug. Mark the spark plug locations before removing them.
Disconnect the LH spark plug wires from the LH spark plugs and remove the ignition coil.
30. Remove the RH exhaust manifold.
31. Remove the bolt and detach the ground strap.
32. Remove the LH side hydraulic chain tensioner.
33. Install the special tools.
^ Tighten the top clamp bolts to 10 Nm (89 lb-inch).
34. Remove the LH camshaft sprocket bolt.
35. Remove the LH timing drive cassette upper bolt.
36. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
Both sides
37. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Remove the cylinder heads.
^ Remove the cylinder head bolts in the sequence shown. Discard all bolts.
^ Remove and discard the head gasket.
Installation
Both sides
1. CAUTION: 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.
Clean and inspect the mating surfaces.
2. Inspect the cylinder head and the cylinder block for flatness.
3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
4. Position the cylinder head gasket on the block.
RH side
5. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).
6. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).
7. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
8. NOTE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
Remove the rubber band. Install the camshaft sprocket and bolt.
9. Install the RH timing drive cassette upper bolt.
^ Tighten to 10 Nm (89 lb-inch).
10. Position the wiring harness bracket and install the bolt.
^ Tighten to 28 Nm (21 lb-ft).
11. Install the RH exhaust manifold.
12. Install the RH inner fender splash shield.
13. Install new wiring harness retainers and attach the wiring harness.
14. Connect the CKP sensor electrical connector.
15. Position the generator bracket and install the bolts.
^ Tighten to 42 Nm (31 lb-ft).
16. Position the accessory drive belt tensioner and install the bolt.
^ Tighten to 47 Nm (35 lb-ft).
17. Connect the generator electrical connectors and install the nut.
^ Tighten to 8 Nm (71 lb-inch).
LH side
18. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).
19. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 lb-ft).
20. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
21. NOTE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
Remove the rubber band. Install the camshaft sprocket and bolt.
22. Install the LH timing drive cassette upper bolt.
^ Tighten to 12 Nm (9 lb-ft).
23. Position the ground strap and install the bolt.
^ Tighten to 25 Nm (18 lb-ft).
24. Install the LH exhaust manifold.
25. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.
Position the ignition coil in the engine compartment and connect the spark plug wires to the LH spark plugs.
26. Install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 lb-inch).
27. Attach the wiring harness to the LH cylinder head and install the bolt.
^ Tighten to 10 Nm (89 lb-inch).
28. Position the power steering and A/C compressor bracket and install the bolts.
^ Tighten to 42 Nm (31 lb-ft).
Both sides
29. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
30. NOTE: You must time the LH and RH camshafts when either camshaft is disturbed.
NOTE: Install the hydraulic chain tensioners during camshaft timing.
Time the camshafts.
31. NOTE: Inspect the thermostat housing O-ring seal. Install a new O-ring seal if necessary.
Position the thermostat housing, making sure the bypass hose is connected to the water pump, and install the bolts.
^ Tighten to 11 Nm (8 lb-ft).
32. Position the bypass hose clamp.
33. Connect the ECT sensor electrical connector.
34. Position the fuel rail and fuel injector assembly and install the bolts.
^ Tighten to 23 Nm (17 lb-ft).
35. Connect the spring lock coupling.
36. Install the roller followers.
37. Install the cooling fan shroud.
38. Install the intake manifold.
39. Fill and bleed the engine cooling system.