Special Tools

Warning: Refer to Safety Glasses Warning in the Preface section.




1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Drain the engine coolant. Refer to Cooling System Draining and Filling.



4. Disconnect the breather tube from the valve cover.
5. Disconnect the intake air temperature (IAT) sensor connector.
6. Disconnect the air intake tube from the throttle body.



7. Remove the air filter housing bolts.
8. Remove the air filter housing.



9. Disconnect the A/C pressure transducer (ACP) connector.



10. Disconnect the idle air control (IAC) valve connector.
11. Disconnect the throttle position (TP) sensor connector.
12. Disconnect the throttle cable from the throttle body and the intake manifold.
13. Disconnect the engine coolant inlet/outlet hose at the throttle body.



14. Disconnect the manifold absolute pressure (MAP) sensor connector.
15. Disconnect the brake booster vacuum hose.
16. Disconnect the variable geometry induction solenoid (VGIS) connector.
17. Disconnect the VGIS vacuum tank hose.



18. Remove the engine cover bolts and cover.
19. Disconnect the breather tube from the valve cover.
20. Disconnect the crankcase ventilation tube from the valve cover.



21. Disconnect the camshaft position (CMP) sensor connector.
22. Disconnect the ignition wires from the spark plugs.
23. Disconnect the fuel injector harness connectors.



24. Disconnect the fuel line.



25. Remove the power steering pressure pipe bracket nut.
26. Remove the power steering pressure pipe.
27. Remove the alternator adjusting nut.



28. Remove the accessory drive bolt.
29. Disconnect the exhaust gas recirculation (EGR) valve connector.
30. Disconnect the electronic ignition (EI) system ignition coil connector.
31. Disconnect the front heated oxygen sensor (HO2S) connector.



32. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation.
33. Remove the engine under cover bolt and the nuts.
34. Remove the engine under cover.
35. Remove the canister purge solenoid valve at the intake manifold support bracket.



36. Remove the upper intake manifold support bracket bolts.
37. Remove the lower intake manifold support bracket bolts.
38. Disconnect the engine coolant temperature (ECT) sensor connector.



39. Remove the exhaust manifold heat shield bolts.
40. Remove the exhaust manifold heat shield.



41. Remove the catalytic converter retaining nuts at the exhaust manifold.



42. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
43. Disconnect the upper radiator hose from the thermostat housing.



44. Remove the upper front timing belt cover bolts.
45. Remove the upper front timing belt cover.



46. Remove the crankshaft pulley bolt.
47. Remove the crankshaft pulley.



48. Remove the lower front timing belt cover bolts.
49. Remove the lower front timing belt cover.



50. Align the camshaft gear timing marks.



51. Slightly loosen the coolant pump retaining bolts.
52. Rotate the coolant pump counterclockwise using the J 42492-A  (1) to relieve the timing belt tension.
53. Remove the timing belt. Refer to Timing Belt Replacement.



54. Remove the valve cover. Refer to Valve Rocker Arm Cover Replacement.

Caution: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

55. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
56. Remove the intake camshaft gear.
57. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
58. Remove the exhaust camshaft gear.



59. Remove the timing belt automatic tensioner bolts.
60. Remove the timing belt automatic tensioner.



61. Remove the camshaft position (CMP) sensor bolts.
62. Remove the CMP sensor.



63. Remove the timing belt idler pulley bolt.
64. Remove the timing belt idler pulley.



65. Remove the rear timing belt cover bolts.
66. Remove the rear timing belt cover.



67. Disconnect the heater outlet hose from the coolant pipe.



68. Loosen all of the cylinder head bolts gradually and in the sequence shown.
69. Remove the cylinder head bolts.
70. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

Caution: Use extreme care when removing the cylinder head to prevent any engine oil , dirt, or coolant from entering the engine. Damage to the engine could result.

71. Remove the cylinder head gasket.

1. Install the cylinder head gasket.
2. Install the cylinder head with the intake manifold and the exhaust manifold attached.
3. Install the cylinder head bolts.

Caution: Refer to Fastener Caution in the Preface section.

4. Tighten the cylinder head bolts gradually and in the sequence shown.

Tighten
Tighten the cylinder head bolts to 25 N·m (18 lb ft). Adjust the bolts to 60 degrees plus 60 degrees plus 60 degrees plus 10 degrees using the J 45059 or KM-470-B .




5. Connect the heater outlet hose from the coolant pipe.



6. Install the rear timing belt cover.
7. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolts to 10 N·m (89 lb in).




8. Install the CMP sensor.
9. Install the CMP sensor bolts.

Tighten
Tighten the CMP sensor bolts to 12 N·m (106 lb in).




10. Install the timing belt idler pulley.
11. Install the timing belt idler pulley bolt.

Tighten
Tighten the timing belt idler pulley bolt to 40 N·m (30 lb ft).




12. Install the timing belt automatic tensioner.
13. Install the timing belt automatic tensioner bolts.

Tighten
Tighten the timing automatic tensioner bolts to 25 N·m (18 lb ft).





Caution: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

14. Install the intake camshaft gear.
15. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten
Tighten the intake camshaft gear bolt to 67.5 N·m (49 lb ft).

16. Install the exhaust camshaft gear.
17. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten
Tighten the exhaust camshaft gear bolt to 67.5 N·m (49 lb ft).




18. Apply a small amount of gasket sealant to the corners of the front camshaft caps, and the top of the rear valve cover to cylinder head seal.
19. Install the valve cover and the valve cover gasket.
20. Install the valve cover bolts.

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




21. Align the timing marks on the camshaft gear.



22. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.




Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

23. Install the timing belt.
24. Rotate the coolant pump clockwise using the J 42492-A  (1) to apply tension to the timing belt.

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

25. Check and adjust the timing belt tension. Refer to Timing Belt Inspection.



26. Install the engine mount-to-engine mount bracket retaining bolts.

Tighten
Tighten the engine mount-to-engine mount bracket retaining bolts to 60 N·m (44 lb ft).

27. Install the lower front timing belt cover.
28. Install the lower front timing belt cover bolts.

Tighten
Tighten the lower front timing belt cover bolts to 10 N·m (89 lb in).




29. Install the crankshaft pulley.
30. Install the crankshaft pulley bolt.

Tighten
Tighten the crankshaft pulley bolt to 95 N·m (70 lb ft) using a torque wrench. Using the J 45059 or KM-470-B , tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.




31. Install the upper front timing belt cover.
32. Install the upper front timing belt cover bolts.

Tighten
Tighten the upper front timing belt cover bolts to 10 N·m (89 lb in).




33. Connect the upper radiator hose from the thermostat housing.
34. Connect the throttle body coolant hose at the thermostat housing.



35. Install the catalytic converter retaining nuts at the exhaust manifold flange.

Tighten
Tighten the catalytic converter retaining nuts to 40 N·m (30 lb ft).




36. Install the exhaust manifold heat shield.
37. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 15 N·m (11 lb ft).




38. Connect the ECT sensor connector.
39. Install the intake manifold support bracket upper bolts.

Tighten
Tighten the intake manifold support bracket upper bolts to 25 N·m (18 lb ft).




40. Install the canister purge solenoid valve at the intake manifold support bracket.
41. Install the engine under cover.



42. Connect the front HO2S connector.
43. Connect the EI system ignition coil connector.
44. Connect the EGR valve connector.

Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

45. Install the accessory drive belt.



46. Install the alternator bracket retaining nut.

Tighten
Tighten the alternator bracket retaining nut to 25 N·m (18 lb ft).

47. Install the alternator nut. Do not tighten.



48. Connect the fuel line at the fuel rail.



49. Connect the fuel injector harness connectors.
50. Connect the ignition wires from the spark plugs.
51. Connect the CMP sensor connector.



52. Connect the crankcase ventilation tube from the valve cover.
53. Connect the breather tube from the valve cover.
54. Install the engine cover.
55. Install the engine cover bolts.



56. Connect the VGIS vacuum tank hose.
57. Connect the VGIS connector.
58. Connect the brake booster vacuum hose.
59. Connect the MAP sensor connector.



60. Connect the engine coolant inlet/outlet hose from the throttle body.
61. Connect the throttle cable from the throttle body and the intake manifold.
62. Connect the TP sensor connector.
63. Connect the IAC valve connector.



64. Connect the A/C pressure transducer connector.



65. Install the air filter housing.
66. Install the air filter housing bolts.

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




67. Connect the air intake tube from the throttle body.
68. Connect the IAT sensor connector.
69. Connect the breather tube from the valve cover.
70. Install the fuel pump fuse.
71. Connect the negative battery cable.
72. Fill the engine cooling system. Refer to Cooling System Draining and Filling.