Tools Required

Caution: Refer to Compressed Valve Spring Caution in the Preface section.

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




1. Remove the fuel pump fuse.
2. Start the engine and wait for it to stall.
3. Crank the engine for 10 seconds to rid the fuel system of fuel pressure.

Caution: Refer to Battery Disconnect Caution in the Preface section.

4. Disconnect the negative battery cable.
5. Disconnect the engine control module (ECM) ground terminal.
6. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.



7. Disconnect the intake air temperature (IAT) sensor and connector.
8. Disconnect the breather tube from the valve cover.
9. Disconnect the crankshaft ventilation tube from the valve cover.
10. Disconnect the vacuum line from the valve cover.
11. Remove the resonator retaining bolts and the resonator.
12. Remove the air intake tube.
13. Remove the canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.



14. Disconnect the ignition coil connector.
15. Disconnect the oxygen sensor connector if equipped.
16. Disconnect the idle air control (IAC) valve connector.
17. Disconnect the throttle position (TP) sensor connector.
18. Disconnect the engine coolant temperature (ECT) sensor connector.
19. Disconnect the coolant temperature sensor (CTS) connector.
20. Disconnect the camshaft position (CMP) sensor connector.



21. Remove the bolts with the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
22. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
23. Remove the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
24. Install the J 28467-B .
25. Remove the right engine mount bracket and the retaining bolt and nuts.



26. Disconnect the upper radiator hose at the thermostat housing.

Caution: Refer to Belt Dressing Notice in the Preface section.

27. Remove the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement in Power Steering System.
28. Remove the crankshaft pulley bolts.
29. Remove the crankshaft pulley.



30. Remove the front timing belt cover bolts.
31. Remove the front timing belt cover.



32. Remove the timing belt. Refer to Timing Belt Replacement .
33. Remove the spark plug cover bolts.
34. Remove the spark plug cover.
35. Disconnect the ignition wires from the spark plugs.
36. Remove the valve cover bolts.
37. Remove the valve cover washers.
38. Remove the valve cover and the valve cover gasket.




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

39. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
40. Remove the intake camshaft gear.
41. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
42. Remove the exhaust camshaft gear.



43. Remove the rear timing belt cover bolts.

Notice: Refer to Fastener Notice in the Preface section.

44. Install the right engine mount bracket, the retaining bolt, and the nuts.

Tighten
Tighten the right engine mount bracket retaining bolt and nuts to 60 N·m (44 lb ft).

45. Remove J 28467-B .



46. Remove the exhaust manifold heat shield nuts and the heat shield.



47. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.



48. Remove the auxiliary catalytic converter upper flange nuts.
49. Disconnect the vacuum hoses, as needed.



50. Disconnect the fuel return line at the fuel pressure regulator.
51. Disconnect the fuel feed line at the fuel rail.
52. Disconnect the coolant hose at the rear cylinder head and ignition coil exhaust gas recirculation (EGR) bracket.
53. Disconnect the surge tank coolant hose at the throttle body.
54. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.



55. Remove the alternator-to-intake manifold support bracket bolts at the cylinder head coolant bypass and the intake manifold.
56. Remove the alternator support bracket.
57. Remove the intake manifold-to-alternator strap bracket bolt and loosen the bolt on the alternator.
58. Move the strap clear of the intake manifold.
59. Remove the canister purge solenoid bracket bolt and move the bracket clear, if equipped.



60. Disconnect the throttle cable at the throttle body and the intake manifold.
61. Loosen all of the cylinder head bolts gradually and in the sequence shown.
62. Remove the cylinder head bolts.
63. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

Important: Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head.

64. Remove the cylinder head gasket.
65. Clean the gasket surfaces of the cylinder head and the engine block. Refer to Cylinder Head Cleaning and Inspection .

Caution: Refer to Compressed Valve Spring Caution in the Preface section.




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.

Notice: Refer to Fastener Notice 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) and turn the bolts another 3 turns of 90 degrees using J 45059 or the KM-470-B .




5. Connect the throttle cable at the throttle body and the intake manifold.
6. Install the alternator-to-intake manifold support bracket.
7. Install the alternator-to-manifold support bracket bolts.

Tighten
Tighten the alternator-to-intake manifold support bracket bolts at the intake manifold to 35 N·m (26 lb ft).

8. Install the intake manifold support bracket bolts to the alternator.

Tighten
Tighten the alternator-to-intake manifold support bracket bolts at the alternator to 20 N·m (15 lb ft).




9. Connect the surge tank coolant hose at the throttle body.
10. Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket.
11. Connect the fuel feed line at the fuel rail.
12. Connect the fuel return line at the fuel rail.
13. Connect all of the necessary vacuum hoses.
14. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.



15. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.

Tighten
Tighten the exhaust flex pipe retaining nuts to 22 N·m (16 lb ft).




16. Install the auxiliary catalytic converter nuts.

Tighten
Tighten the auxiliary catalytic convert-to-exhaust manifold nuts to 40 N·m (30 lb ft).




17. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 8 N·m (71 lb in).

18. Install the J 28467-B .
19. Remove the right engine mount bracket, the retaining bolt, and the nuts.



20. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolts to 7 N·m (62 lb in).




21. Install the camshaft gears with the timing marks at the front.
22. Insert the guide pin of the intake camshaft into the IN bore.
23. Insert the guide pin of the exhaust camshaft into the EX bore.



24. Install the camshaft gears by counterholding on the hex of the camshaft with an open-ended wrench.
25. Install the intake camshaft gear with a new bolt to the camshaft.

Tighten
Tighten the intake camshaft gear bolt to 50 N·m (37 lb ft), turn the bolt another 60 degrees and 15 degrees using the J 45059 or the KM-470-B .

26. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten
Tighten the exhaust camshaft gear bolt to 50 N·m (37 lb  ft), turn the bolt another 60 degrees and 15 degrees using the J 45059 or the KM-470-B .




27. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear valve cover-to-cylinder head seal.
28. Install the valve cover and the valve cover gasket.
29. Install the valve cover washers.
30. Install the valve cover bolts.

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




31. Connect the ignition wires to the spark plugs.
32. Install the spark plug cover.
33. Install the spark plug cover bolts.

Tighten
Tighten the spark plug cover bolts to 3 N·m (27 lb in).

34. Align the timing marks on the camshaft gears to the notches on the valve cover, using the intake gear (1) mark for the intake gear and the exhaust gear mark for the exhaust gear (2).



35. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.



36. Install the timing belt. Refer to Timing Belt Replacement .
37. Check and adjust the timing belt tension. Refer to Timing Belt Inspection .



38. Install the front timing belt cover.
39. Install the front timing belt cover bolts.

Tighten
Tighten the upper and lower front timing belt cover bolts to 6 N·m (53 lb in).

40. Install the crankshaft pulley.
41. Install the crankshaft pulley bolts.

Tighten
Tighten the crankshaft pulley bolts to 20 N·m (15 lb ft).




42. Install the right engine mount bracket, the retaining bolts, and the nut.

Tighten
Tighten the right engine mount bracket retaining bolt and nuts to 60 N·m (44 lb ft).

43. Remove the J 28467-B .

Notice: Refer to Belt Dressing Notice in the Preface section.

44. Install the power steering pump. Refer to Power Steering Pump Belt Replacement in Power Steering System.
45. Connect the upper radiator hose to the thermostat housing.
46. Install the front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
47. Install the right front wheel . Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



48. Install the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
49. Connect the air intake tube to the throttle body.
50. Connect the vacuum line to the valve cover.
51. Connect the crankshaft ventilation tube from the valve cover.
52. Connect the breather tube to the valve cover.
53. Connect the manifold air temperature sensor connector.
54. Install the resonator retaining bolts.

Tighten
Tighten the resonator retaining bolts to 3 N·m (27 lb in).




55. Connect the CMP sensor connector.
56. Connect the CTS connector.
57. Connect the ECT sensor connector.
58. Connect the IAC valve connector.
59. Connect the TP sensor connector.
60. Install the canister purge solenoid bracket bolt.

Tighten
Tighten the canister purge solenoid bracket bolt to 5 N·m (44 lb in).




61. Connect the ignition coil connector.
62. Connect the oxygen sensor connector, if equipped.
63. Connect the ECM ground terminal.
64. Install the fuel pump fuse.
65. Connect the negative battery ground cable.
66. Refill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.