Tools Required

1. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Drain the engine oil.
5. Remove the washer fluid tank mounting bolt.
6. Position the washer fluid tank aside.
7. Disconnect the washer pump connector.
8. Disconnect the washer pump fluid line.
9. Plug the washer pump fluid line in order to prevent washer fluid from escaping.



10. Remove the serpentine drive belt. Refer to Drive Belt Replacement .



11. Disconnect the generator connector.
12. Disconnect the positive cable at the generator.



13. Remove the two generator bolts.
14. Remove the generator (1).



15. Remove the accelerator cable from the throttle body (1).



16. Disconnect the intake air temperature (IAT) sensor.
17. Remove the air cleaner hose and cap assembly (1).

Disconnect the throttle position (TP) sensor connector.

18. Disconnect the idle air control (IAC) Valve connector.
19. Disconnect the manifold absolute pressure (MAP) sensor connector.
20. Remove the two coolant bypass hose clamps from the throttle body.
21. Remove the coolant bypass hoses.



22. Disconnect the four fuel injector connectors.
23. Remove the upper radiator hose.
24. Remove the following items from the intake manifold:

•	The two bolts (3, 4)

•	The fuel injector harness

25. Position the fuel injector harness above the intake manifold.
26. Remove the intake manifold support bracket bolts and bracket.
27. Disconnect all of the necessary vacuum hoses.
28. Remove the fuel injector harness brackets.
29. Disconnect the oxygen sensor connector.
30. Remove the oxygen sensor nuts.
31. Remove the following components:

•	The oxygen sensor

•	The oxygen sensor gasket

32. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



33. Remove the following items from the exhaust pipe at the manifold.

•	The two bolts (1, 2)

•	The springs

34. Remove the exhaust pipe to manifold seal.



35. Remove the one bolt (1) from the exhaust manifold to the support bracket.
36. Lower the vehicle.



37. Install the engine support fixture J 28467-A. Refer to Engine Support Fixture .
38. Remove the following items from the right side engine mount:

•	The two nuts

•	The four bolts

39. Loosen the air conditioning receiver pinch clamp.
40. Lift the air conditioning receiver in order to gain access to the right side engine mount.
41. Remove the right side engine mount.
42. Disconnect the two ignition coil connectors.
43. Disconnect the fuel line at the fuel rail.
44. Remove the injector fuel rail hold down clamp.



45. Remove the ignition coils (1, 2, 3, 4).
46. Remove the following items from the cylinder head:

•	The three bolts

•	The fuel rail

•	The two ground wire bolts

•	The ground wires

47. Position the injector harness aside.
48. Remove the heater hose at the cylinder head.
49. Remove the following items from the cylinder head:

•	The one bolt

•	The water bypass pipe

50. Remove the following items:

•	The one bolt

•	The camshaft sensor

51. Remove the engine coolant temperature sensor.
52. Remove the following items from the cylinder head cover:

•	The two PCV hoses

•	The PCV valve

53. Remove the cylinder head cover from the cylinder head. Refer to Cylinder Head Cover Replacement .
54. Set the number one piston to top dead center.
55. Align the camshaft timing sprockets.
56. Disconnect the power steering oil pressure switch connector.
57. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
58. Remove the right side lower engine splash shield.



59. Remove the two power steering pump through bolts and nuts (1).
60. Remove the power steering pump.
61. Position the power steering pump aside.
62. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement .



63. Remove the following items:

•	The crankshaft position sensor bolt (5)

•	The crankshaft position sensor

64. Lower the vehicle.
65. Remove the drive belt tensioner nut.
66. Remove the following items:

•	The drive belt tensioner bolt

•	The drive belt tensioner

67. Remove the following items:

•	The three right side engine mounting bracket bolts

•	The engine mounting bracket




68. Remove the timing chain tensioner bolts (1, 2).
69. Remove the timing chain tensioner.



70. Remove the timing chain cover bolts and nuts (1-15).
71. Remove the timing chain cover.
72. Remove the crank sensor reluctor.
73. Remove the following items:

•	The timing chain slipper bolt

•	The slipper




74. Remove the following items:

•	The crankshaft sprocket

•	The timing chain




75. Remove the camshaft sprocket bolts.
76. Remove the camshaft sprockets.



77. Remove the following items in sequence:

•	The camshaft bearing cap bolts

•	The camshaft bearing caps

78. Remove the camshafts.
79. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location.

Important: Use a wooden block in order to protect the oil pan when lifting the engine.

80. Use a floor jack in order to raise the engine.
81. Reposition the holding fixture.
82. Remove the Intake Manifold. Refer to Intake Manifold Replacement .
83. Remove the Exhaust Manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.



84. Remove the following items in sequence:

•	The cylinder head bolts

•	The cylinder head washers




85. Remove the cylinder head.



86. Remove the cylinder head gasket (1).



87. Clean the cylinder block mating surfaces.



88. Clean the cylinder head mating surface.
89. Clean the timing chain cover mating surface.

Notice: This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.

1. Clean the threads in the cylinder block.
2. Install the new cylinder head gasket on the cylinder block.
3. Install the cylinder head on the cylinder block.

Notice: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.

4. Install the cylinder head bolts and washers into the 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.

5. Progressively torque the cylinder head bolts using three steps in the sequence shown.

1st Pass
Tighten the cylinder head bolts to 25 N·m (18 lb ft).

2nd Pass
Tighten the cylinder head bolts to 49 N·m (36 lb ft).

3rd Pass
After reaching the torque of 49 N·m (36 lb ft). Use a J 36660-A and tighten the cylinder head bolts an additional 90 degrees.

Important: Use a wooden block in order to protect the oil pan when lifting the engine.

6. Use a floor jack in order to raise the engine.
7. Reposition the holding fixture.
8. Support the engine by the support hook.
9. Lower the floor jack.
10. Install the intake camshaft. Refer to Intake Camshaft and Valve Lifter Replacement .
11. Install the exhaust camshaft. Refer to Exhaust Camshaft and Valve Lifter Replacement .
12. Install the timing chain. Refer to Timing Chain and Sprocket Replacement .
13. Install the timing chain housing. Refer to Timing Chain Housing Replacement .
14. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
15. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement .
16. Install the engine coolant temperature (ECT) sensor.
17. Install the camshaft sensor.
18. Use the one bolt in order to secure the camshaft sensor.

Tighten
Tighten the camshaft sensor bolt to 15 N·m (11 lb ft).




19. Install the water bypass pipe (1) to the cylinder head.
20. Use the one bolt in order to secure the coolant bypass pipe to the cylinder head.

Tighten
Tighten the coolant bypass pipe to 15 N·m (11 lb ft).

21. Install the heater hose to the cylinder head.
22. Install the engine ground wires to the cylinder head.
23. Use the two bolts in order to secure the engine ground wires.

Tighten
Tighten the ground wire bolts to 15 N·m (11 lb ft).

24. Install the fuel rail to the cylinder head.
25. Use the three bolts in order to secure the fuel rail.

Tighten
Tighten the fuel rail bolts to 14 N·m (10 lb ft).

26. Connect the fuel line to the fuel rail.



27. Install the four ignition coils (1, 2, 3, 4).
28. Connect the ignition coil connectors.



29. Install the right side engine mount.
30. Use the two nuts (3) and the four bolts (1, 2, 4, 5) in order to secure the right side engine mount:

Tighten
Tighten the right side engine mount bolts and nuts to 54 N·m (40 lb ft).

31. Tighten the air conditioning receiver pinch clamp.
32. Remove the engine support fixture.
33. Raise and support the vehicle.



34. Install the one bolt (1) from the manifold to the support bracket.

Tighten
Tighten the exhaust support bracket bolt to 35 N·m (26 lb ft).




35. Use a new seal in order to install the exhaust pipe to the exhaust manifold.
36. Use the two bolts and two springs (1, 2) in order to secure the exhaust pipe.

Tighten
Tighten the exhaust pipe flange bolts to 62 N·m (46 lb ft).

37. Lower the vehicle.
38. Install the oxygen sensor and the oxygen sensor gasket.
39. Install the two oxygen sensor nuts.

Tighten
Tighten the heated oxygen sensor nuts to 41 N·m (30 lb ft).

40. Connect the oxygen sensor connector.
41. Install the injector harness brackets.
42. Connect all of the necessary vacuum hoses.
43. Install the intake manifold support bracket.
44. Use the support bracket bolts in order to secure the intake manifold support bracket.

Tighten
Tighten the intake support bracket bolts to 50 N·m (37 lb ft).

45. Install the fuel injector harness to the intake manifold.
46. Use the three bolts in order to secure the fuel injector harness.

Tighten
Tighten the fuel injector harness bolts to 12 N·m (106 lb in).

47. Install the upper radiator hose.
48. Connect the four fuel injector connectors.
49. Connect the temperature sensor connector.
50. Install the two coolant bypass hoses to the throttle body.
51. Use the two hose clamps in order to secure the two coolant bypass hoses.
52. Connect the MAP sensor connector.
53. Connect the IAC valve connector.
54. Connect the TP sensor connector.
55. Install the air cleaner hose and cap assembly.
56. Connect the IAT sensor connector.
57. Install the accelerator cable to the throttle body.



58. Install the generator (1). Refer to Generator Replacement in Engine Electrical.
59. Connect the positive cable to the generator.



60. Connect the generator connector.



61. Install the serpentine drive belt. Refer to Drive Belt Replacement .
62. Remove the washer pump outlet plug.
63. Connect the washer pump fluid line.
64. Connect the washer pump connector.
65. Install the washer fluid tank.
66. Use the one bolt in order to secure the washer fluid tank.

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

67. Refill the engine oil.
68. Refill the engine coolant.