Removal & Installation
Relieve the fuel system pressure.
CAUTIONFuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.
- Disconnect the negative battery cable.
Drain the engine oil and the cooling system.
NOTEBefore disconnecting any hoses or connectors, note the locations for reassembly.
- Remove the air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses.
- Remove the fuel hoses and disconnect the harness connections.
- Disconnect the canister purge hoses.
- Disconnect and remove all six ignition coils from the spark plugs.
- Remove the bolts that secure the EGR tube and remove the tube.
- Remove the intake manifold collector supports and remove the collector. Remove the manifold from the cylinder head.
- Remove the cylinder head covers from the cylinder head.
- Remove the right front wheel and engine side covers.
- Remove the drive belts and idler pulley followed by the power steering oil pump belt and remove the power steering oil pump assembly.
- Remove the camshaft position sensor (PHASE) and crankshaft position sensors (REF)/(POS).
- Set the No. 1 piston to TDC of compression stroke by rotating the crankshaft.
- Remove the ring gear cover access plate and remove the crankshaft pulley bolt.
- Remove the timing chain tensioner and slack side chain guide.
Remove the engine oil pan.
- Remove the camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
NOTEKeep all bearing caps and camshafts in proper order for reinstallation.
- Remove the cylinder head bolts in sequence.
Turn the crankshaft until the No. 1 piston is set 240 degrees before TDC on compression stroke.
Using new head gaskets, install the cylinder heads.
NOTEIf possible, replacement of the head bolts is suggested.
If replacement of the head bolts is not possible, perform the following bolt measurement:
- Measure the diameter of the head bolt 0.43 inches (11mm) from the bottom of the bolt.
- Measure the diameter of the head bolt 1.89 inches (48mm) from the bottom of the bolt.
- Whenever the size difference between the two measurements exceeds 0.0043 inches (0.11mm) the head bolts must be replaced.
- Install the cylinder head bolts and tighten in sequence.
Install the camshaft tensioners. Tighten the tensioner mounting bolts to 75-96 inch lbs. (8.4-10.8 Nm).
NOTEThe camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.
NOTEWhen installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.
- Install the camshafts and install the bearing caps.
- Install new O-rings to the front of the engine block.
- Install the crankshaft sprocket with the mating mark facing out.
- Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position.
- Install the lower chain guide on the dowel pin with the front mark on the guide facing upward.
- Install the timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks.
- Remove the left and right camshaft tensioner stopper pins.
- Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.
- Attach the lower timing chain to the water pump sprocket.
- Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.
- Install the intake sprocket bolts and tighten to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.
- Install the timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide.
- Install the timing cover evenly and gently. Be sure to align the dowel pin holes. Tighten the mounting bolts in sequence.
- Install the front exhaust pipe and its support.
- Install the A/C compressor and bracket.
- Install the crankshaft pulley to the crankshaft and install the mounting bolt.
- Tighten the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Tighten the crankshaft bolt an additional 60-66 degrees clockwise. This is about the angle from one hexagon bolt head corner to another.
- Install the ring gear cover plate.
- Install the camshaft position sensor (PHASE) and crankshaft position sensors (REF)/(POS).
- Install the power steering pump assembly.
- Install the drive belts and the idler pulley.
- Install the right front inner wheel cover and install the right front wheel.
- Install the engine undercovers.
- Using new gaskets, install the intake manifold. Tighten the nuts and bolts in sequence.
- Install the intake manifold collector gasket with the arrow facing forward.
- Install the intake manifold collector assembly and tighten the mounting bolts to 16-18 ft. lbs. (22-25 Nm).
- Install the intake manifold collector support brackets.
- Using new gaskets, install the EGR tube and tighten the mounting bolts to 15-20 ft. lbs. (21-26 Nm) in two progressive steps.
- Install the spark plugs.
- Install the ignition coils and tighten the mounting bolts to 27-33 inch lbs. (2.9-3.8 Nm).
- Install the cylinder head cover ornament on the left side.
- Install the water hoses to the cylinder head and intake manifold.
- Connect the canister purge hoses.
- Connect the fuel hoses and wiring harness connections to the fuel rail.
- Install and connect the air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses.
- Refill the engine crankcase and cooling system with the proper type and amount of fluid.
- Connect the negative battery cable.
- Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
- Verify that there are no leaks.