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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


J3B11CA6
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Engine Cover

Removal Procedure

  1. Remove the bolts and nuts from the engine cover.
  2. Remove the engine cover.

J3B11CA7
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Installation Procedure

  1. Position the engine cover on the engine.
  2. Install the engine cover bolts and nuts.

    3. Tighten
    Tighten the engine cover bolts and nuts to 10 N•m(89 lb-ft).


J3B11CA8
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Camshaft Cover

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to "Engine" in this section.
  3. Remove the breather hose, ventilation hose and cam position sensor wiring connector from the camshaft cover.

    4. J3B11CA9
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  4. Remove the ignition wires from the spark plug.
  5. Remove the camshaft cover bolts and camshaft cover.
  6. Remove the camshaft cover gasket.

J3B11CB1
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Installation Procedure

  1. Install the camshaft cover gasket on the camshaft cover.
  2. Position the camshaft cover on the engine block.
  3. Install the camshaft cover bolts.

    4. Tighten
    Tighten the camshaft cover bolts to 10 N•m(89 lb-ft).

  4. Install the ignition wires to the spark plugs and connect the breather hose, ventilation hose and cam position sensor wiring connector to the canshaft cover.
  5. Install the engine cover.
  6. Connect the negative battery cable.

J3B11CB2
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Intake Manifold

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery calbe.
  4. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

    5. J3B11CA6
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  5. Remove the engine cover and throttle body. Refer to Section 1F, Engine Control.

    6. J3B11CB3
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  6. Disconnect the intake manifold pressure sensor connector, attaching bolt and vaccum hose.

    7. J3B11CB4
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  7. Disconnect the intake manifold air temperature sensor(MAT) connector and remove the MAT sensor.

    8. J3B11CB5
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  8. Remove the intake manifold upper bracket.
  9. Remove the fule rail bolt and the fuel rail.

    10. J3B11CB6
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  10. Remove the all the vaccum hoses from the intake manifold including PCV hose and brake booster vaccum hose.
  11. Remove the exhaust gas recirculation(EGR) pipe.

    12. J3B11C19
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  12. Remove the alternator. Refer to Section 1E, Engine Electrical.
  13. Remove the intake manifold support bracket.

    14. J3B11CB8
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  14. Remove the intake manifold retaining bolts/nuts in the sequence shown.
  15. Remove the intake manifold and gasket.
  16. Clean the sealing surfaces of the intake manifold and the cylinder head.

J3B11CB9
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Installation Procedure

  1. Install the fule rail.

    2. Tighten
    Tighten the fule rail bolts to 25 N•m (18 lb-ft).

  2. Install the new intake manifold gasket and intake manifold.

    3. Tighten
    Tighten the intake manifold bolts and nuts to 25 N•m (18 lb-ft).


    J3B11CC1
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  3. Install the exhaust gas recirculation(EGR) pipe.

    4. Tighten
    Tighten the exhaust gas recirculation(EGR) pipe bolts to 10 N•m (89 lb-ft).


    J3B11CC2
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  4. Install the intake manifold support bracket.

    5. Tighten
    Tighten the intake manifold support bracket upper bolts to 25 N•m (18 lb-ft) and lower bolts to 45 N•m (33 lb-ft).

  5. Install the alternater.

    6. J3B11CB5
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  6. Install the fuel rail.
  7. Install the fuel rail bolts.
  8. Install the intake manifold upper bracket.
  9. Install the intake manifold upper bracket bolts.

    10. J3B11CB4
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  10. Install the intake manifold air temperature sensor(MAT) and connect the MAT sensor connecter.

    11. J3B11CB3
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  11. Install the intake manifold pressure sensor and vaccum hose.

    12. J3B11CA6
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  12. Install the throttle body and engine cover.
  13. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.
  14. Install the fuel pump fuse and connect the negative battery cable.

J3B11CC3
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Exhaust Manifold

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the oxygen sensor connecter.
  3. Remove the exhaust manifold heat shield.

    4. J3B11CC4
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  4. Remove the exhaust manifold nuts from the pup converter.

    5. J3B11CC5
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  5. Remove the exhaust manifold retaining nuts in the sequence shown and remove the exhaust manifold.
  6. Remove the exhaust manifold gasket.
  7. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

J3B11CC6
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Installation Procedure

  1. Install the exhaust manifold and gasket.
  2. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

    3. Tighten
    Tighten the exhaust manifold retaining nuts to 25 N•m (18 lb-ft).


    J3B11CC4
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  3. Install the exhaust manifold nuts to the catalytic converter.

    4. Tighten
    Tighten the exhaust manifold nuts to 40 N•m (30 lb-ft).


    J3B11CC3
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  4. Install the heat shield.

    5. Tighten
    Tighten the the heat shield bolts to 13 N•m (10 lb-ft).

  5. Connect the oxygen sensor connecter.
  6. Connect the negative battery cable.

J3B11CB2
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Cylinder Head and Gasket

Tools Required

J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery calbe.
  4. Disconnect the electronic control module(ECM) ground terminal from the intake manifold.
  5. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

    6. J3B11CC7
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  6. Drain the engine oil and remove the camshaft cover. Refer to this section.
  7. Remove the air cleaner housing.

    8. J3B11CC8
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  8. Remove the throttle cable and inlet/outlet coolant hoses.

    9. J3B11CC9
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  9. Remove the thermostat upper hose.

    10. J3B11CB7
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  10. Remove the intake manifold pressure sensor, intake air temperature sensor and coolant temperature sensor.
  11. Remove the intake manifold support bracket.

    12. J3B11CD1
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  12. Remove the all the vaccum hoses from the intake manifold including brake booster vaccum hose.
  13. Remove the ignition cables from the spark plugs.
  14. Remove the direct ignition coil(DIS) and the bracket from the cylinder head.

    15. J3B11CD2
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  15. Remove the serpentine accessory drive belt by rotating the tensioner pulley bolt to clockwise using DW110-080. Refer to Section 6B, Power Steering Pump.

    16. J3B11CD3
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  16. Remove the front passenger side tire. Refer to Section 2E, Tires and Wheels.
  17. Remove front wheel housing shield.

    18. J3B11CD4
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  18. Remove the upper front timing belt cover bolts.
  19. Remove the upper front timing belt cover.
  20. Align the camshaft gear timing marks.
  21. Remove the crank shaft pulley.
  22. Remove the lower front timing belt cover bolts and cover.

    23. J3B11CD5
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  23. Slightly loosen the water pump retaining bolts.
  24. Rotate the water pump counterclockwise using the timing belt adjuster J-42492 to relieve the timing belt tension.
  25. Remove the timing belt.Refer to "Timing Belt" in this section.

    26. J3B11CD6
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  26. Remove the engine mounting bracket.Refer to "Engine Mount" in this section.
  27. Remove the camshaft cover. Refer to "Camshaft Cover" in this section.

    28. J3B11CD7
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  28. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and gear.
  29. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and gear.

    30. Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.


    J3B11CD8
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  30. Remove the timing belt automatic tensioner.
  31. Remove the timing belt idler pulley.
  32. Remove the right engine mount. Refer to "Engine Mount" in this section.
  33. Remove the rear timing belt cover.

    34. J3B11CD9
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  34. Remove the intake/exhaust manifold. Refer to "Intake/Exhaust Manifold" in the section.
  35. Remove the cylinder head bolts gradually in the sequence shown and remove the cylinder head.

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

  36. Remove the cylinder head gasket.

J3B11CE1
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Cleaning Procedure

  1. Clean the gasket sitting surfaces of the cylinder head and the engine block.
  2. Make sure the gasket sitting surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
  3. Clean the cylinder head bolts.
  4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve Train Components" in this section.

Installation Procedure

  1. Install the new cylinder head gasket.
  2. Install the intake/exhaust manifold to the cylinder head. Refer to "Intake/Exhaust Manifold" in the section.
  3. Install the cylinder head bolts gradually in the sequence shown.

    4. J3B11CE2
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    Tighten
    Tighten the cylinder head bolts to 25 N•m (18 lb-ft) and retighten the cylinder head bolts 70 degrees plus 70 degrees plus 50 degrees using the angular torque gauge KM-470-B.

  4. Install the right engine mount. Refer to "Engine Mount" in this section.

    5. J3B11CB7
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  5. Connect the throttle cable at the throttle body and the intake manifold.
  6. Install the intake manifold support bracket upper bolts to the intake manifold.

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

  7. Connect the surge tank coolant hose at the throttle body.
  8. Connect the heater inlet hose to the cylinder head.

    9. J3b11CI1
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  9. Install the generator upper retaining bolt.

    10. Tighten
    Tighten the generator upper retaining bolt to 20 N•m (15 lb-ft).

  10. Connect the fuel feed line at the fuel rail.
  11. Connect all the disconnected vacuum hoses and the brake booster vacuum hose at the intake manifold.

    12. J3B11CC4
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  12. Install the catalytic converter retaining nuts at the exhaust manifold flange.

    13. Tighten
    Tighten the catalytic converter to exhaust manifold flange nuts to 40 N•m (30 lb-ft).


    J3B11CD8
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  13. Install the rear timing belt cover.
  14. Install the rear timing belt cover bolts.

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


    J3B11CE4
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  15. Install the timing belt automatic tensioner.

    16. Tighten
    Tighten the timing belt automatic tensioner bolts to 25 N•m (18 lb-ft).

  16. Install the timing belt idler pulley.

    17. Tighten
    Tighten the timing belt idler pulley bolt to 25 N•m(18 lb-ft).


    J3B11CD7
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    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  17. Install the intake/exhaust camshaft gear.

    18. Tighten
    Tighten the intake/exhaust camshaft gear bolts to 67.5 N•m (49 lb-ft).


    J3B11CK2
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  18. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover-to-cylinder head seal.
  19. Install the camshaft cover and the gasket. Refer to "Camshaft Cover" in this section.

    20. J3D11C02
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  20. Connect the ignition wires to the spark plugs.
  21. Install the oil filler cap.
  22. Connect the engine ventilation hose to the camshaft cover.
  23. Align the timing marks on the camshaft gears.
  24. Align the mark on the crank shaft gear with the notch at the bottom of the rear timing belt cover.

    25. J3B11CE7
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  25. Install the timing belt.
  26. Rotate the water pump clockwise using the timing belt adjuster J-42492 to apply tension to the timing belt.

    27. Tighten
    Tighten the water pump retaining bolts to 10 N•m (89 lb-in).

  27. Check and adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.

    28. J3B11CE8
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  28. Install the upper and lower front timing belt covers.

    29. Tighten
    Tighten the upper and lower front timing belt covers bolts to 10 N•m (89 lb-in).

  29. Install the crank shaft pulley bolt.

    30. Tighten
    Tighten the crank shaft pulley bolt to 95 N•m (70 lb-ft) and retighten 30 degrees plus 15 degrees.


    J3B11CD3
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  30. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  31. Connect the upper radiator hose to the thermostat housing.
  32. Install the front wheel and splash shield. Refer to Section 2E, Tires and Wheels.

    33. J3B11CB4
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  33. Install the air cleaner housing.

    34. Tighten
    Tighten the air cleaner housing bolts to 10 N•m (89 lb-in).

  34. Connect the breather tube to the cam shaft cover.
  35. Install the crank shaft pulley bolt.
  36. Connect the MAT sensor connector.
  37. Connect the intake manifold pressure sensor, intake air temperature sensor and coolant temperature sensor connector.

    38. J3B11CE9
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  38. Connect the DIS coil connector.
  39. Connect the fuel injector harness connectors.
  40. Connect the oxygen sensor connector and the ECM ground terminal at the intake manifold.
  41. Install the fuel pump fuse.
  42. Connect the negative battery ground cable.
  43. Refill the engine cooling system. Refer to Section1D, Engine Cooling.

J3B11CA9
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Camshafts

Removal Procedure

  1. Remove the camshaft cover. Refer to "Camshaft Cover" in this section.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.

    3. J3B11CD7
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    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  3. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and gear.
  4. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and gear.

    5. J3B11CF1
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  5. Remove the camshaft cap bolts gradually in the sequence shown for each camshaft cap.

    6. J3B11CF2
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  6. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation.
  7. Remove the intake/exhaust camshaft.

J3B11CF1
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Installation Procedure

    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  1. Lubricate the camshaft journals and the camshaft caps with engine oil.
  2. Install the intake/exhaust camshafts.
  3. Install the intake/exhaust camshaft caps in their original positions.

    4. Tighten
    Tighten the intake/exhaust camshaft caps bolts to 16 N•m (12 lb-ft).


    J3B11CF3
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  4. Measure the intake/exhaust camshaft end play.Refer to the "Engine Specifications" in this section.
  5. Install the intake/exhaust camshaft gear.
  6. While holding the intake/exhaust camshafts firmly in place, install the intake/exhaust camshaft gear bolts.

    7. Tighten
    Tighten the intake/exhaust camshaft gear bolts to 67.5 N•m (49 lb-ft).


    J3B11CA9
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  7. Install the timing belt. Refer to "Timing Belt" in this section.
  8. Install the camshaft cover. Refer to "Camshaft Cover" in this section.

J3B11CF4
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Timing Belt Check and Adjust

Tools Required

J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge

Adjustment Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner outlet hose from the throttle body.
  3. Remove the breather tube from the camshaft cover.

    4. J3B11CC7
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  4. Remove the air cleaner housing bolts.
  5. Remove the air cleaner housing.
  6. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  7. Remove the right front wheel well splash shield.

    8. J3B11CD4
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  8. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  9. Remove the crankshaft pulley bolt.
  10. Remove the crankshaft pulley.

    11. J3B11CF5
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  11. Remove the upper front timing belt cover bolts.
  12. Remove the upper front timing belt cover.
  13. Remove the lower front timing belt cover bolts.
  14. Remove the lower front timing belt cover.
  15. Install the crankshaft pulley bolt.

    16. J3D11C02
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  16. Rotate the crankshaft at least one full turn clockwise using the crankshaft pulley bolt.
  17. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
  18. Align the camshaft gear timing marks.

    19. J3B11CD5
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  19. Slightly loosen the water pump retaining bolts.
  20. Rotate the water pump clockwise using the timing belt adjuster J-42492.

    21. J3B11CF6
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  21. Rotate the water pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.

    22. J3B11CE8
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  22. Tighten the water pump retaining bolts.
  23. Rotate the crankshaft two full turns clockwise using the crankshaft pulley.
  24. Loosen the water pump retaining bolts.

    25. J3B11CF7
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  25. Using the timing belt adjuster J-42492, rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.

    26. J3B11CF8
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  26. Tighten the water pump retaining bolts.

    27. Tighten
    Tighten the water pump retaining bolts to 10 N•m (89 lb-in).

  27. Remove the crankshaft pulley bolt.
  28. Install the upper and lower front timing belt covers.
  29. Install the upper and lower front timing belt cover bolts.

    30. Tighten
    Tighten the front timing belt cover bolts to 10 N•m (89 lb-in).


    J3B11CE8
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  30. Install the crankshaft pulley.
  31. Install the crankshaft pulley bolt.

    32. Tighten
    Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft) and retighten 30 degrees plus 15 degrees.

  32. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.

    33. J3B11CC7
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  33. Install the right front wheel well splash shield.
  34. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
  35. Install the air cleaner housing.
  36. Install the air cleaner housing bolts.

    37. Tighten
    Tighten the air cleaner housing bolts to 10 N•m (89 lb-in).


    J3B11CF4
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  37. Connect the air cleaner outlet hose to the throttle body.
  38. Connect the breather tube to the camshaft cover.
  39. Connect the negative battery cable.

J3B11CF4
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Timing Belt

Tools Required

J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the air cleaner outlet hose from the throttle body.
  3. Disconnect the breather tube from the camshaft cover.

    4. J3B11CC7
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  4. Remove the air cleaner housing bolts.
  5. Remove the air cleaner housing.
  6. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  7. Remove the right front wheel well splash shield.

    8. J3B11CD4
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  8. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  9. Remove the crankshaft pulley bolt.
  10. Remove the crankshaft pulley.

    11. J3B11CF5
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  11. Remove the upper front timing belt cover bolts.
  12. Remove the upper front timing belt cover.
  13. Remove the lower front timing belt cover bolts.
  14. Remove the lower front timing belt cover.
  15. Install the crankshaft pulley bolt.

    16. J3B11CF9
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  16. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.

    17. J3B11CD5
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  17. Slightly loosen the water pump retaining bolts.
  18. Using the timing belt adjuster J-42492, rotate the water pump counterclockwise to release the tension on the timing belt.
  19. Remove the right engine mount bracket. Refer to "Engine Mount" in this section.

    20. J3B11CG1
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  20. Remove the timing belt.

J3D11C02
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Installation Procedure

  1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
  2. Align the timing marks on the camshaft gears.

    3. J3B11CG2
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  3. Install the timing belt.
  4. Install the right engine mount bracket. Refer to "Engine Mount" in this section.

    5. J3B11CF6
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  5. Rotate the water pump clockwise using the timing belt adjuster J-42492.
  6. Rotate the water pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.

    7. J3B11CF7
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  7. Tighten the water pump retaining bolts.
  8. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
  9. Loosen the water pump retaining bolts.
  10. Rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.

    11. J3B11CE8
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  11. Tighten the water pump retaining bolts.

    12. Tighten
    Tighten the water pump retaining bolts to 10 N•m (89 lb-in).


    J3B11CF8
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  12. Remove the crankshaft pulley bolt.
  13. Install the upper and lower front timing belt covers.
  14. Install the upper and lower front timing belt cover bolts.

    15. Tighten
    Tighten the front timing belt cover bolts to 10 N•m (89 lb-in).


    J3B11CE8
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  15. Install the crankshaft pulley.
  16. Install the crankshaft pulley bolt.

    17. Tighten
    Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft) and retighten 30 degrees plus 15 degrees.

  17. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  18. Install the right front wheel well splash shield.
  19. Install the right front wheel. Refer to Section 2E, Tires and Wheels.

    20. J3B11CC7
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  20. Install the air cleaner housing.
  21. Install the air cleaner housing bolts.

    22. Tighten
    Tighten the air cleaner housing bolts to 10 N•m (89 lb-in).

  22. Connect the air cleaner outlet hose to the throttle body.
  23. Connect the breather tube to the camshaft cover.
  24. Connect the negative battery cable.


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