Tools Required

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .



2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the positive crankcase ventilation (PCV) fresh air vent hose at the cam cover.
7. Remove outlet resonator/duct assembly.
8. Remove the air cleaner assembly hold-down bolt.
9. Remove the air cleaner assembly.



10. Remove the ignition module bolts.
11. Remove the ignition module assembly.



12. Disconnect engine control module (ECM) electrical connector and ground at ECM.
13. Remove oil level indicator bolt to manifold.
14. Disconnect the electrical connector at the throttle body.
15. Disconnect the electrical connector at the fuel injector harness and the attachment at bottom of the intake manifold.
16. Disconnect the electrical connector at purge solenoid and manifold absolute pressure (MAP) sensor.
17. Disconnect the vacuum hose at the brake booster.



18. Disconnect the coolant pipe bracket bolts to front of cylinder head.



19. Disconnect the degas hose at clamp at the cylinder head and unclip from the fuel rail. Position away from the cam cover assembly.
20. Disconnect ground strap at rear of the cam cover assembly.



21. Relieve fuel system pressure. Refer to Fuel Pressure Relief .
22. Disconnect the SA9127E after pressure has been relieved.



23. Disconnect the fuel rail bracket and bolt at the rear cam cover.




Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.

Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.

24. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at the fuel rail.



25. Position the fuel line away from the cam cover assembly.
26. Remove the cam cover assembly bolts.
27. Remove the cam cover assembly.

Notice: To avoid valve piston contact, No. 1 cylinder piston must be positioned at approximately 60 degrees before-top dead center (BTDC). Pistons are properly positioned when the diamond shaped hole on the intake camshaft sprocket is located at 12 o'clock.

Important: To rotate camshafts, use a 24 mm open-end wrench on camshaft flats. Camshafts should be rotated in a clockwise direction only, facing camshaft sprockets from passenger side of vehicle.




28. Locate the No.1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.



29. Remove upper timing chain guide.




Important: The timing chain tensioner must be removed to unload chain tension before timing chain is removed. If it is not removed, the timing chain may bind and be difficult to remove.

30. Remove the timing chain tensioner.



31. Remove the fixed timing chain guide access plug.
32. Using a magnetic socket, remove the upper fixed guide bolt.



33. Install SA9105E set up for SUV application. Also, use J 45122 with long hooks from J 43405 . Refer to Engine Support Fixture .



34. Remove the right-hand engine mount-to-bracket bolts.
35. Remove the right-hand mount assembly nuts.
36. Remove the right-hand engine mount assembly.



37. Remove the right-hand mount bracket.
38. Remove the right-hand engine mount bracket.
39. Raise the vehicle on hoist.
40. Remove the right wheel and splash shield.
41. Remove J 44811 .
42. Remove the accessory drive belt.
43. Remove the tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.



44. Remove the tensioner assembly.



45. Install J 38122-A .




Important: The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a threw-jay puller.

46. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.




Notice: To avoid damage to the front cover assembly, do not pry against the cover.

47. Remove the front cover assembly bolts.
48. Remove the lower water pump assembly bolt.
49. Remove the front cover assembly and gasket.



50. Drain the coolant system. Refer to Cooling System Draining and Filling .



51. Remove the exhaust manifold pipe to the manifold nuts.
52. Disconnect the electrical connectors at the front and rear oxygen sensors.
53. Remove down pipe to intermediate pipe nuts.
54. Remove down pipe assembly.
55. Lower the vehicle.



56. Remove the upper radiator hose from cylinder head.




Notice: The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY) bolt, and must be discarded to prevent premature failure.

57. Use a 24 mm wrench to hold the camshaft assembly while removing the exhaust sprocket bolt. Discard the bolt.
58. Remove the exhaust sprocket.



59. Remove the adjustable guide through the top of the cylinder head.



60. Remove the fixed timing chain guide.



61. Use a 24 mm wrench to hold the camshaft assembly while removing the intake sprocket bolt. Discard the bolt.
62. Remove the intake sprocket.
63. Remove the timing chain assembly through top of cylinder head.
64. Remove the timing chain drive sprocket from the crankshaft.



65. Remove the timing chain oiling nozzle and remove any debris from hole in block.




Important: Replace timing chain guides if wear exceeds 1.12 mm (0.045 in).

66. Inspect timing chain guide for wear.
67. Inspect the timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on the chain.




Caution: Do not raise the vehicle without the right hand mount or the engine support fixture attached. Bodily harm or engine mount damage may occur.

68. Install floor jack with block of wood and support the engine at the center of the oil pan.
69. Remove engine three bar engine support fixture to allow cylinder head to be removed.



70. Remove cylinder head bolts using loosening sequence.
71. With assistance, remove the cylinder head from block with the exhaust and intake manifold attached.

Notice: Set crankshaft to 60 degrees before top-dead center or after TDC to prevent valve to piston contact.

1. Transfer all components. (intake manifold, plugs, ect.).



2. Set crankshaft to 60 degrees before top dead center.



3. Install the cylinder head gasket placing OPEN facing up.




Important: Always use new cylinder head bolts.

4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
5. Lightly apply clean engine oil to threads and to the bottom side of flange of head bolts. Allow oil to drain before installing.

Notice: Refer to Fastener Notice in the Preface section.

6. Install and torque cylinder head bolts in sequence.

Tighten
Tighten the cylinder head bolts to 30 N·m (22 lb ft) + 155 degrees.




7. Coat the front cylinder head crankcase bolts with Permatex® Threadlocker® Blue. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

Tighten
Tighten the cylinder head front chaincase bolts to 35 N·m (24 lb ft).




8. Install the SA9105E that was removed earlier.



9. Position the exhaust camshaft with offset slot to the 10 o'clock position.



10. Position the intake camshaft with offset slot to the 2 o'clock position.



11. Install timing chain drive sprocket to the crankshaft.
12. Using dampener, rotate the crank so that the mark on the timing chain drive sprocket is at the 5 o'clock position.



13. Install timing chain oiling nozzle and bolt.

Tighten
Tighten the timing chain oil nozzle bolt to 10 N·m (89 lb ft).




14. Assemble the chain to the intake camshaft sprocket aligning the copper link to INT diamond timing mark on camshaft sprocket.




Important: When lowering the timing chain into the cylinder head, rotate the assembly 90 degrees to allow the chain to fall between the cylinder block bosses, then rotate assembly back to that the camshaft sprocket is facing forward.

15. Lower assembly through chain housing opening on top of the cylinder head. Use care to make sure that the chain goes around both sides of the cylinder block bosses.




Important: The crankshaft sprocket timing mark will be at approximately the 5 o'clock position.

16. Route chain around crankshaft sprocket and align silver link to timing mark.




Notice: The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY) bolt, and must be discarded to prevent premature failure.

17. Install the intake camshaft sprocket with the chain in the proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.

Important: With the timing chain aligned to crankshaft sprocket mark, the crankshaft can be rotated slightly to eliminate slack from the fixed side of the timing chain. Be sure that the marks are properly aligned.

18. Install new intake camshaft sprocket bolt and finger tighten.




Important: Make sure the crankshaft marks and the camshaft marks aligns with the colored links.

19. Install adjustable timing chain guide through the opening at the top of the cylinder head and install chain guide bolt.

Tighten
Tighten the timing chain guide adjustable bolt to 10 N·m (89 lb in).




20. Install exhaust camshaft sprocket loosely on exhaust camshaft with timing mark on sprocket aligned with silver link.
21. Install new camshaft sprocket bolt loosely.



22. Align the exhaust camshaft sprocket with the chain in proper position to the camshaft. Rotate exhaust clockwise using a 24 mm wrench on flats on camshaft until the camshaft aligns with sprocket.



23. Verify that all colored links are aligned with the appropriate intake (1), crankshaft sprocket (2), and exhaust marks.
24. Verify crankshaft sprocket timing mark is at the 5 o'clock position.
25. If marks are not correct you must repeat the timing procedure.



26. Install the fixed timing chain guide and bolts.

Tighten
Tighten the timing chain fixed bolts to 15 N·m (133 lb in).




27. Apply thread sealant Permatex® Thread Pipe Sealant (or equivalent) compound to the thread. Install the fixed guide bolt access hole plug.

Tighten
Tighten the timing chain guide bolt access hole plug to 40 N·m (30 lb ft).





Notice: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage the timing chain.

28. Tighten the intake and exhaust camshaft sprocket bolts while holding the camshaft with 24 mm wrench.

Tighten
Tighten the camshaft sprocket bolts to 85 N·m (63 lb ft) +30 degrees.




29. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring or washer is damaged replace the timing chain tensioner.

Important: A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (1) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (1) from end to end.

30. Measure the timing chain tensioner assembly from end to end.



31. If the timing chain tensioner is not in the compressed state, perform the following steps:

31.1.

Remove the piston assembly from the body of the timing chain tensioner by pulling it out.

31.2.

Install J 45027  (2) into a vise.

31.3.

Install notch end of piston assembly into J 45027  (2).

31.4.

Using J 45027  (1), turn the ratchet cylinder into the piston.




32. Inspect the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with lint free cloth.
33. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
34. At this point the tensioner should measure approximately 72 mm (2.83 in)  (1) from end to end. If the tensioner does not read 72 mm (2.83 in)  (1) from end to end repeat step 30.



35. Ensure all dirt and debris is removed from the timing chain tensioner threaded hold in the cylinder head.
36. Install new timing chain tensioner assembly and tighten.

Tighten
Tighten the timing chain tensioner assembly bolt to 75 N·m (55 lb ft).

37. The timing chain tensioner is released by compressing it 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.



38. Install upper timing chain guide and bolts.

Tighten
Tighten the timing chain guide upper bolts to 10 N·m (89 lb ft).

39. Raise the vehicle if necessary.
40. Install new front cover gasket.
41. Install the front cover assembly.
42. Install the front cover assembly bolts.

Tighten
Tighten the front cover-to-block bolts to 25 N·m (18 lb ft).

43. Install the front cover water pump bolts.

Tighten
Tighten the water pump bolts to 25 N·m (18 lb ft).




44. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
45. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
46. Install the crankshaft damper pulley.



47. Install new crankshaft balancer pulley bolt with washer assembly.



48. Install crankshaft pulley holder J 38122-A .

Tighten
Tighten the crankshaft pulley bolt to 100 N·m (74 lb ft) +75.




49. Install accessory drive belt tensioner.

Tighten
Tighten the drive belt tensioner bolt to 50 N·m (37 lb ft).

50. Route belt around the alternator and the A/C compressor.
51. Install J 39914 onto tensioner and upload spring tension from tensioner while positioning belt.
52. Release tensioner and remove the tool.
53. Position manifold down pipe with gasket onto flange studs.
54. Install exhaust manifold pipe to exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 30 N·m (22 lb ft).

55. Attach electrical harness at bottom intake manifold.
56. Position oil level indicator into oil pan assembly.
57. Install oil level indicator tube bolt.

Tighten
Tighten the oil level indicator-to-manifold bolt to 10 N·m (89 lb in).

58. Remove the oil drain plug and drain oil.

Tighten
Tighten the oil drain plug to 25 N·m (18 lb ft).

59. Lower the vehicle.
60. Remove the oil filter and install a new oil filter.
61. Fill the engine with oil.

Tighten
Tighten the oil filter cap to 25 N·m (18 lb ft).




62. Install right-hand engine bracket and bolts.

Tighten
Tighten the engine mount bracket-to-engine bolts to 90 N·m (66 lb ft).




63. Install shims on right hand engine mount studs.
64. Install right-hand engine mount onto body side rail studs.
65. Install right-hand engine mount to body nuts.

Tighten
Tighten the engine mount-to-body nuts to 110 N·m (81 lb ft).

66. Install right-hand engine mount to engine mount bracket bolts.

Tighten
Tighten engine mount-to-engine mount bracket bolts to 55 N·m (41 lb ft).

67. Install the right engine inner splash shield.
68. Install the right wheel and hand-tighten wheel nuts.
69. Tighten wheel nuts.

Tighten
Tighten wheel nuts to 125 N·m (92 lb ft).




70. Remove three bar engine support fixture.



71. Visually inspect the camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
72. Assemble the camshaft cover and gasket using care to make sure that the gasket is located in the retaining groove on the camshaft cover.
73. Install cover on the cylinder head and tighten the bolts.

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




74. Position engine harness and install fasteners at cam cover.
75. Connect the throttle body connector.
76. Attach ECM ground and ECM connector.
77. Connect the fuel injector harness.
78. Connect the upper radiator hose.
79. Connect the brake booster hose at booster
80. Connect evaporative emission (EVAP) purge hose and connector.
81. Connect the oxygen sensors at the exhaust manifold.



82. Reposition the fuel line assembly.

Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.

83. Install transfer line at fuel-to-fuel rail.

Tighten
Tighten the transfer line fitting-to-fuel rail to 10 N·m (89 lb in).




84. Connect the fuel rail bracket and bolt to the cylinder head.

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




85. Connect the ground strap to the camshaft cover assembly.

Tighten
Tighten the camshaft cover ground strap bolts to 10 N·m (89 lb in).

86. Connect the degas hose and attach to the fuel fail.
87. Connect the coolant pipe bracket bolts to the cylinder head.

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




88. Install spark plugs, if removed.

Tighten
Tighten the spark plugs to 20 N·m (15 lb ft).

89. Install the ignition module assembly to cam cover and hand tighten retaining bolts.

Tighten
Tighten the ignition module-to-camshaft cover bolts to 8 N·m (71 lb in).




90. Install air cleaner assembly and bolt.

Tighten
Tighten air cleaner-to-support bracket bolt to 10 N·m (89 lb in).

91. Install outlet resonator/duct assembly into position.
92. Connect PCV fresh air vent hose assembly.
93. Tighten clamp at throttle body assembly.
94. Position outlet resonator/duct assembly up with support bracket and install push-pin.
95. Tighten the clamp at the air cleaner assembly.
96. Connect IAT sensor connector.
97. Install coolant. Refer to Cooling System Draining and Filling .
98. Connect negative battery cable.

Tighten
Tighten the battery terminal bolt to 17 N·m (13 lb ft).

99. Start the vehicle and inspect for leaks.