MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE


Valve Cover
Removal Procedure
- Disconnect the negative battery cable.
- Disconnect the breather hose from the valve cover.


- Remove the eight bolts from the valve cover.
- Remove the valve cover.
- Remove the valve cover gasket.
- Clean the sealing surfaces of the valve cover and the camshaft housing.


Installation Procedure
- Install the new valve cover gasket and the valve cover.
- Install the eight bolts to the valve cover.
Tighten
Tighten the valve cover bolts to 10 N•m (89 lb-in).


- Connect the breather tube to the valve cover.
- Connect the negative battery cable.


Cylinder Head and Gasket
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Removal Procedure
- Remove the fuel pump fuse.
- Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
- Disconnect the negative battery cable.
- Disconnect the engine control module (ECM) ground terminal from the intake manifold.


- Drain the engine coolant. Refer to Section 1D, Engine Cooling.
- Disconnect the intake air temperature (IAT) sensor connector.
- Disconnect the breather tube from the valve cover.
- Disconnect the air intake tube from the throttle body.


- Disconnect the electronic ignition (EI) system ignition coil connector.
- Disconnect the coolant temperature sensor (CTS) connector. Refer to Section 1F, Engine Control.


- Disconnect the idle air control (IAC) valve connector.
- Disconnect the throttle position (TP) sensor connector.


- Remove the camshaft position (CMP) sensor.


- Remove the air cleaner housing bolts.
- Remove the air cleaner housing.


- Remove the upper timing belt cover bolts.
- Remove the upper timing belt cover.


- Align the camshaft gear timing mark to the notch in the rear timing belt cover.


- Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
- Remove the right front wheel well splash shield.
- Remove the serpentine accessory drive belt.


- Disconnect the fuel feed line at the fuel rail.


- Remove the power steering pipe bracket mounting nut. Refer to Section 6B, Power Steering Pump.
- Remove the alternator nut.
- Remove the alternator bracket retaining nut.
- Remove the alternator bracket.


- Disconnect the brake booster vacuum hose at the intake manifold.
- Disconnect all of the necessary vacuum hoses and electrical connector.
- Disconnect the Map sensor from the intake manifold.


- Remove the crankshaft pulley bolt.
- Remove the crankshaft pulley.
- Remove the lower timing belt cover bolts.
- Remove the lower timing belt cover.


- Slightly loosen the coolant pump retaining bolts.
- Remove the coolant pump counterclockwise using the timing belt adjuster L-42492 to relieve the timing belt tension.
- Remove the timing belt. Refer to "Timing Belt"
in this section.


- Disconnect the crankcase ventilation tube at the
camshaft housing.


- Remove the valve cover bolts.
- Remove the valve cover and the valve cover gasket.
Notice : Take care to prevent any scratches, nicks or
damage to the camshaft.
- While holding the camshaft firmly in place, remove
the camshaft gear bolt.
- Remove the camshaft gear.


- Remove the rear timing belt cover upper bolts.


- Disconnect the ignition wires at the spark plugs.
- Remove the retaining nuts from the catalytic
converter at the exhaust manifold flange.
- Disconnect the front heated oxygen sensor electrical connector.


- Disconnect the heater inlet hose at the coolant distributor.
- Disconnect the surge tank coolant hose at the
throttle body.


- Remove the intake manifold support bracket retaining
bolts.


- Disconnect the throttle cable at the throttle body and
the intake manifold.


- Gradually loosen all of the cylinder head bolts in the
sequence shown.
- Remove the cylinder head bolts.
- Remove the camshaft carrier assembly.
Notice : Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head. Damage
to the engine could result.
- Remove the cylinder head with the intake manifold
and the exhaust manifold attached.
- Remove the cylinder head gasket.


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


Installation Procedure
- Apply a continuous 3 mm (0.12 inch) bead of gasket
maker to the sealing surface of the camshaft carrier.
- Install the cylinder head gasket.
- Install the cylinder head with the intake manifold and
the exhaust manifold attached.
- Install the camshaft carrier assembly.


- Install the cylinder head bolts in the sequence shown.


Tighten
Tighten the cylinder head bolts in the sequence previously shown to 25 N•m (18 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the cylinder head bolts another 70 degrees plus 70 degrees plus 30 degrees.


- Connect the throttle cable at the throttle body and at
the intake manifold.


- Install the intake manifold support bracket retaining
bolt.
Tighten
Tighten the intake manifold support bracket retaining
bolts to 25 N•m (18 lb-ft).


- Connect the surge tank coolant hose at the throttle
body.
- Connect the heater inlet hose to the coolant distributor.


- Install the catalytic converter nuts at the exhaust
manifold flange.
Tighten
Tighten the auxiliary catalytic converter-to-exhaust manifold nuts to 40 N•m (30 lb-ft).
- Connect the front heated oxygen sensor electrical connector.


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


Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can impair
vehicle operation.
- Install the camshaft gear.
- While holding the crankshaft pulley bolt, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 N•m (33 lb-ft).


- Connect the crankcase ventilation tube to the camshaft
housing.


- Align the mark on the camshaft gear to the notch at
the top of the rear timing belt cover.


- Align the mark on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.
- Install the timing belt. Refer to "Timing Belt" in this
section.
- Check the timing belt tension. Refer to "Timing Belt
Check and Adjust" in this section.
- Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 N•m (89 lb-ft).


- Install the crankshaft pulley.
- Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolts to 95 N•m (70 lb-in) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.
- Connect all of the vacuum hoses and electrical connectors.
- Connect the brake booster hose at the intake manifold.
- Connect the upper radiator hose at the thermostat housing.


- Install the alternator bracket.
- Install the alternator bracket retaining nut.
Tighten
Tighten the alternator bracket retaining nut to 25 N•m (18 lb-ft).
- Install the alternator nut. Do not tighten.


- Connect the fuel feed line at the fuel rail.


- Install the serpentine accessroy drive belt. Refer to Section 6B, Power Ssteering Pump.
- Install the upper timing belt cover.
- Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 N•m (89 lb-in).
- Install the A/C compressor drive belt, as necessary.
- Install the right front wheel well splash shield.
- Install the right front wheel. Refer to Section 2E,
Tires and Wheels.


- Install the air filter housing.
- Install the air filter housing bolts.
Tighten
Tighten the air filter housing bolts to 8 N•m (71 lb-in).
- Connect the air intake tube to the throttle body.
- Connect the breather tube to the valve cover.
- Connect the IAT sensor connector.
- Install the CMP sensor.


- Connect the CTS connector.
- Connect the IAC valve connector.
- Connect the TP sensor connector.
- Connect the EI system ignition coil connector.
- Connect the fuel injector harness connectors.
- Connect the O2 sensor connector.
- Connect the PCM/ECM ground terminal at the intake
manifold.
- Connect the negative battery cable.
- Install the fuel pump fuse.
- Refill the engine cooling system. Refer to Section
1D, Engine Cooling.


Camshaft
Tools Required
KM-565-A Valve Spring Compressor
Removal Procedure
- Remove the timing belt. Refer to "Timing Belt" in this
section.
- Disconnect the air breather tube at the valve cover.
- Remove the valve cover bolts.
- Remove the valve cover.
- Remove the valve cover gasket.


- Install the valve spring compressor KM-565-A.
Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can impair
vehicle operation.
- Remove the roller followers using the valve
spring compressor KM-565-A.


- While holding the camshaft firmly in place, remove
the camshaft gear bolt.
- Remove the camshaft gear.


- Disconnect the positive battery cable from the battery.
- Remove the battery and the battery tray. Refer to Section 1E, Engine Electrical.


- Disconnect the electronic ignition (EI) system ignition
coil connector.
- Disconnect the EI system ignition wires at the ignition
coil.
- Remove the EI system ignition coil mounting nuts.
- Remove the EI system ignition coil.


- Remove the EI system ignition coil mounting plate
bolts.
- Remove the EI system ignition coil mounting plate.


- Remove the camshaft pressure plate bolts.
- Remove the camshaft pressure plate.


- Remove the camshaft.


Installation Procedure
- Install the camshaft.
- Install the camshaft pressure plate.
- Install the camshaft pressure plate bolts.
Tighten
Tighten the camshaft pressure plate bolts to 10 N•m (89 lb-in).
- Measure camshaft end play. Camshaft end play
should be 0.09~0.21 mm


- Install the EI system ignition coil mounting plate.
- Install the EI system ignition coil mounting plate
bolts.
Tighten
Tighten the EI system ignition coil mounting plate
bolts to 10 N•m (89 lb-in).


- Install the EI system ignition coil.
- Install the EI system ignition coil mounting bolts.
Tighten
Tighten the EI system ignition coil mounting bolts to
10 N•m (89 lb-in).
- Connect the ignition wires at the EI system ignition
coil.
- Connect the EI system ignition coil connector.


- Install the battery and the battery tray. Refer to Section
1E, Engine Electrical.
- Connect the positive battery cable to the battery.


Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can impair
vehicle operation.
- Install the camshaft gear.
- While holding the camshaft firmly in place, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 N•m (33 lb-ft).


- Install the camshaft followers using the valve spring
compressor KM-565-A.
- Remove the tool KM-565-A.


- Install the valve cover gasket.
- Install the valve cover.
- Install the valve cover bolts.
Tighten
Tighten the valve cover bolts to 9 N•m (80 lb-in).
- Connect the air breather tube to the valve cover.
- Install the timing belt. Refer to "Timing Belt" in this
section.


Timing Belt Check and Adjust
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Adjustment Procedure
- Disconnect the negative battery cable.
- Disconnect the intake air temperature (IAT) sensor
connector.
- Disconnect the air intake tube from the throttle body.
- Disconnect the breather tube from the valve cover.


- Remove the air cleaner housing bolts.
- Remove the air cleaner housing.
- Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
- Remove the right front wheel well splash shield.


- Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
- Remove the upper timing belt cover bolts.
- Remove the upper timing belt cover.


- Remove the crankshaft pulley bolt.
- Remove the crankshaft pulley.


- Remove the lower timing belt cover bolts.
- Remove the lower timing belt cover.


- Install the crankshaft pulley bolt.
- Rotate the crankshaft at least one full turn clockwise
using the crankshaft pulley bolt.
- Align the dot on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.


- Align the camshaft gear timing mark to the notch at
the top of the rear timing belt cover.


- Slightly loosen the three coolant pump retaining
bolts.
- Using the timing belt adjuster J-42492, rotate the
coolant pump clockwise to add the highest tension
to the timing belt.
- Tighten the coolant pump retaining bolts loosely.


- Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic tensioner
bracket.
- Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.
- Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
- Rotate the crankshaft at least one full turn clockwise
using the crankshaft pulley bolt.
- Remove the driver from the timing belt automatic
tensioner.
- Loosen the coolant pump retaining bolts.


- Rotate the coolant pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the notch in the timing belt automatic tensioner
bracket.
- Tighten the coolant pump retaining bolts.
Tighten
Tighten the coolant pump retaining bolts to 10 N•m (89 lb-in).


- Remove the crankshaft pulley bolt.
- Install the lower timing belt cover.
- Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 N•m (89 lb-in).


- Install the crankshaft pulley.
- Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft)
using a torque wrench. Use the angular torque gauge
KM-470-B to tighten the crankshaft pulley bolt another
30 degrees plus 15 degrees.


- Install the upper timing belt cover.
- Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 N•m (89 lb-in).
- Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.


- Install the right front wheel well splash shield.
- Install the right front wheel. Refer to Section 2E, Tires and Wheels.
- Install the air cleaner housing.
- Install the air cleaner housing bolts.
Tighten
Tighten the air filter housing bolts to 8 N•m (71 lb-in).


- Connect the air intake tube to the throttle body.
- Connect the breather tube to the valve cover.
- Connect the IAT sensor connector.
- Connect the negative battery cable.


Timing Belt
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Removal Procedure
- Disconnect the negative battery cable.
- Disconnect the intake air temperature (IAT) sensor
connector.
- Disconnect the air intake tube from the throttle body.
- Disconnect the breather tube from the valve cover.


- Remove the air cleaner housing bolts.
- Remove the air cleaner housing.
- Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
- Remove the right front wheel well splash shield.


- Remove the serpentine accessory drive bolt. Refer
to Section 6B, Power Steering Pump.
- Remove the upper timing belt cover bolts.
- Remove the upper timing belt cover.


- Remove the crankshaft pulley bolt.
- Remove the crankshaft pulley.
- Remove the lower timing belt cover bolts.
- Remove the lower timing belt cover.


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


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


Installation Procedure
- Align the mark on the crankshaft gear to the notch on
the bottom of the rear timing belt cover.
- Align the mark on the camshaft gear to the notch on
the top of the rear timing belt cover.
- Install the timing belt.


- Using the timing belt adjuster J-42492, rotate the
coolant pump clockwise to add the highest tension to
the timing belt.
- Tighten the coolant pump retaining bolts loosely.


- Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic tensioner
bracket.
- Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.


- Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
- Align themark on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.


- Remove the driver from the timing belt automatic
tensioner.
- Slightly loosen the three coolant pump retaining
bolts.
- Using the timing belt adjuster J-42492, rotate the
coolant pump.


- Rotate the coolant pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the notch in the timing belt automatic tensioner
bracket.
- Tighten the coolant pump retaining bolts.
Tighten
Tighten the coolant pump retaining bolts to 10 N•m (89 lb-in).


- Remove the crankshaft pulley bolt.
- Install the lower timing belt cover.
- Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 N•m (89 lb-in).


- Install the crankshaft pulley.
- Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft) using a torque wrench. Using the angular torque gauge KM-470-B, tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.


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


- Install the serpentine accessory drive belt.


- Install the right front wheel well splash shield.
- Install the right front wheel. Refer to Section 2E, Tires and Wheels.
- Install the air filter housing.
- Install the air filter housing bolts.
Tighten
Tighten the air filter housing bolts to 8 N•m(71 lb-in).


- Connect the air intake tube to the throttle body.
- Connect the breather tube to the valve cover.
- Connect the IAT sensor connector.
- Connect the negative battery cable.
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