For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 36660-A Torque Angle Meter

• | J 28467-A Engine Support Fixture

• | J 8614-01 Pinion Flange Holder

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 in Engine Mechanical.
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 temperature sensor connector (2).
23. Disconnect the four fuel injector connectors.
24. Remove the upper radiator hose.
25. Remove the following items from the intake manifold:

• | The three bolts (3, 4)

• | The fuel injector harness

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

• | The oxygen sensor

• | The oxygen sensor gasket

33. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
34. Remove the following items from the exhaust pipe at the manifold.

• | The two bolts (1,2)

• | The springs

35. Remove the exhaust pipe to manifold seal.
36. Remove the one bolt (1) from the exhaust manifold to the support bracket.
37. Lower the vehicle.
38. Raise and properly support the engine. Refer to Engine Support Fixture in Engine Mechanical.
39. Remove the following items from the right side engine mount:

• | The two nuts

• | The four bolts

40. Loosen the air conditioning receiver pinch clamp.
41. Lift the air conditioning receiver in order to gain access to the right side engine mount.
42. Remove the right side engine mount.
43. Disconnect the two ignition coil connectors.
44. Disconnect the fuel line at the fuel rail.
45. Remove the injector fuel rail hold down clamp.
46. Remove the secondary spark plug wires from the cylinder head cover (1).
47. Remove the four bolts from the ignition coil bracket.
48. Remove the coils with the spark plug wires attached.
49. Remove the following items from the cylinder head:

• | The three bolts

• | The fuel rail

50. Remove the following items from the cylinder head:

• | The two ground wire bolts

• | The ground wires

51. Position the injector harness aside.
52. Remove the heater hose at the cylinder head.
53. Remove the following items from the cylinder head:

• | The one bolt

• | The water bypass pipe

54. Remove the following items:

• | The one bolt

• | The camshaft sensor

55. Remove the engine coolant temperature sensor.
56. Remove the following items from the cylinder head cover:

• | The two PCV hoses

• | The PCV valve

57. Remove the cylinder head cover from the cylinder head. Refer to Cylinder Head Cover Replacement in Engine Mechanical.
58. Set the number one piston to top dead center.
59. Align the camshaft timing sprockets.
60. Disconnect the power steering oil pressure switch connector.
61. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
62. Remove the right side lower engine splash shield.
63. Remove the two power steering pump through bolts and nuts (1).
64. Remove the power steering pump.
65. Position the power steering pump aside.
66. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement in Engine Mechanical.
67. Remove the following items:

• | The crankshaft position sensor bolt (5)

• | The crankshaft position sensor

68. Lower the vehicle.
69. Remove the drive belt tensioner nut.
70. Remove the following items:

• | The drive belt tensioner bolt

• | The drive belt tensioner

71. Remove the following items:

• | The three right side engine mounting bracket bolts

• | The engine mounting bracket

72. Remove the timing chain tensioner bolts (1, 2).
73. Remove the timing chain tensioner.
74. Remove the timing chain cover bolts and nuts (1-15).
75. Remove the timing chain cover.
76. Remove the crank sensor reluctor.
77. Remove the following items:

• | The timing chain slipper bolt

• | The slipper

78. Remove the following items:

• | The crankshaft sprocket

• | The timing chain

79. Remove the camshaft sprocket bolts.
80. Remove the camshaft sprockets (1).
81. Remove the following items in sequence:

• | The camshaft bearing cap bolts

• | The camshaft bearing caps

82. Remove the camshafts.
83. 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.

84. Use a floor jack in order to raise the engine.
85. Reposition the holding fixture.
86. Remove the Intake Manifold. Refer to Intake Manifold Replacement in Engine Machanical.
87. Remove the Exhaust Manifold.Refer to Exhaust Manifold Replacement in Engine Mechanical.
88. Remove the following items in sequence:

• | The cylinder head bolts

• | The cylinder head washers

89. Remove the cylinder head.
90. Remove the cylinder head gasket (1).
91. Clean the cylinder block mating surfaces.
92. Clean the cylinder head mating surface.
93. Clean the timing chain cover mating surface.

### Installation Procedure

1. Install the new cylinder head gasket on the cylinder block.
2. Install the cylinder head on the cylinder block.
3. Install the cylinder head bolts and washers into the cylinder head.
4. 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.

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

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

18. Install the water bypass pipe (1) to the cylinder head.
19. 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).

20. Install the heater hose to the cylinder head.
21. Install the engine ground wires to the cylinder head.
22. 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).

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

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

25. Connect the fuel line to the fuel rail.
26. Install the two ignition coils.
27. Use the four bolts in order to secure the two ignition coils.

Tighten
Tighten the ignition coil bracket bolts to 14 N·m (10 lb ft).

28. Install the secondary spark plug wires (1).
29. Connect the two ignition coil connectors.
30. Install the right side engine mount.
31. 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).

32. Tighten the air conditioning receiver pinch clamp.
33. Remove the engine support fixture.
34. Raise and support the vehicle.
35. Install the one bolt (1) from the manifold to the support bracket.

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

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

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

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

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

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

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

46. Install the fuel injector harness to the intake manifold.
47. 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).

48. Install the upper radiator hose.
49. Connect the four fuel injector connectors.
50. Connect the temperature sensor connector.
51. Install the two coolant bypass hoses to the throttle body.
52. Use the two hose clamps in order to secure the two coolant bypass hoses.
53. Connect the MAP sensor connector.
54. Connect the IAC valve connector.
55. Connect the TP sensor connector.
56. Install the air cleaner hose and cap assembly.
57. Connect the IAT sensor connector.
58. Install the accelerator cable to the throttle body.
59. Install the generator (1). Refer to Generator Replacement in Engine Electrical.
60. Connect the positive cable to the generator.
61. Connect the generator connector.
62. Install the serpentine drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
63. Remove the washer pump outlet plug.
64. Connect the washer pump fluid line.
65. Connect the washer pump connector.
66. Install the washer fluid tank.
67. 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).

68. Refill the engine oil.
69. Refill the engine coolant.