Tools Required

J 43094 Spark Plug Boot Puller

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
2. Remove the PCV vacuum hose (2) from the right camshaft cover.
3. Remove the surge tank inlet hose from the surge tank. Plug the hose.
4. Remove the surge tank nuts, and reposition the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
5. Remove the surge tank inlet hose/pipe bracket bolt.
6. Reposition the surge tank inlet hose/pipe and bracket.
7. If the vehicle is equipped, remove the right AIR check valve and the bracket. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 1 in Engine Controls - 3.5L.
8. Release the clips at the power steering lines. Reposition the lines as necessary.
9. Remove the engine wiring harness channel bolt from the right camshaft cover.
10. Disconnect the electrical connectors from the following:

•	Heated oxygen (HO2S) sensor

•	EVAP canister purge solenoid

•	Fuel injectors

11. Reposition the engine wiring harness and the channel.
12. Remove the engine wiring harness from the retainers at the right camshaft cover.
13. Remove the ignition coil assembly from the right camshaft cover. Refer to Ignition Coil Replacement in Engine Controls - 3.5L.



14. Remove the right camshaft cover bolts.
15. Lift the camshaft cover off the right cylinder head evenly.

Important: The camshaft cover seals should be reused unless they are damaged, or if the perimeter seal is pulled from the groove during removal.

16. Insert the J 43094 and rotate the spark plug boot prior to removing the boot. Remove the spark plug boots using the J 43094 . Inspect the spark plug boots. Replace as necessary.
17. Clean and inspect the camshaft cover. Refer to Camshaft Cover Cleaning and Inspection in Engine Mechanical - 3.5L Unit Repair.

1. Wipe the right cylinder head sealing surface with a clean, lint-free cloth.
2. Inspect the right camshaft cover seals for damage. Verify that the perimeter seal is securely seated in the groove. Replace the seals if damaged, or pulled from the groove.
3. Place the camshaft cover in position, on the right cylinder head.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the right camshaft cover bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

5. Install the ignition coil assembly to the right camshaft cover. Refer to Ignition Coil Replacement in Engine Controls - 3.5L.
6. Install the engine wiring harness to the retainers at the right camshaft cover.
7. Reposition the engine wiring harness and the channel.
8. Connect the electrical connectors to the following:

•	Fuel injectors

•	EVAP canister purge solenoid

•	Heated oxygen (HO2S) sensor

9. Install the engine wiring harness channel bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

10. Install the power steering lines to the retaining clips.
11. Install the right AIR check valve bracket and the AIR check valve, if equipped. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 1 in Engine Controls - 3.5L.
12. Install the surge tank inlet hose/pipe and bracket with the bracket bolt.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

13. Install the surge tank inlet hose to the surge tank.
14. Install the surge tank.



15. Install the PCV vacuum hose (2) to the right camshaft cover.
16. Install the fuel injector sight shield bracket.
17. Install the fuel injector sight shield bracket bolts.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

18. Inspect for leaks.
19. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .