For 1990-2009 cars

• | J 43223 Rocker Arm Removal Tool

• | J 43299 Camshaft Holder

• | SA9104E Front Crank Seal Replacer

• | SA9123E Gasket Seal Cutter

• | SA9124E Regulator Valve Remover/Replacer

• | SA9127E Gage Bar Set

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Important: Camshafts can be removed using the J 43299 . The SA9127E is used for pressurizing the cylinder with 690 kPa (100 psi) of air to hold the valves closed. Valve springs, caps, and stem seals can be replaced without removing the cylinder head using the SA9124E. Rocker arm assemblies can be removed using the J 43223 . Refer to Camshaft and Lifter Replacement and Valve Spring and Stem Seal Replacement In-Vehicle.

1. Disconnect the cable from the negative terminal of the battery and remove the coolant bottle cap.

Notice: The engine's cooling system thermostat and water pump will not function correctly if oil is found in the cooling system. The cooling system must be flushed and the water pump and the thermostat's cartridge replaced.

2. Drain coolant from the radiator and engine. The engine drain is at the right front corner of the engine block under the thermostat housing.
3. Remove the air cleaner cover assembly and air inlet duct. Lift the resonator upward to disengage the button from the engine service support bracket.
4. Disconnect the cam cover air hose at the cam cover.

Important: The throttle body assembly, fuel rail, injectors, and intake manifold can be removed with the cylinder head assembly from the vehicle.

5. Disconnect the accelerator cable from the throttle body and intake manifold bracket.
6. Remove the following electrical connectors:

| Important: Use long nose pliers to remove the coolant temperature connectors.

• | Coolant temperature gage and the PCM connector located at the rear side of the head

• | Injector connectors

• | Idle air control (IAC) valve

• | Throttle position (TP) sensor

• | Manifold air pressure (MAP)

• | Oxygen sensor

• | Spark wires

• | Air conditioner compressor

• | Exhaust gas recirculation (EGR)

7. Lay the harness over onto the underhood junction block and battery cover.
8. Disconnect the following vacuum hoses:

• | EVAP canister purge valve

• | PCV hose at the cam cover

• | Throttle body connector

| Important: The MAP sensor does not require removal.

• | Vacuum brake booster hose at the brake booster

9. Disconnect the following hoses:

| Important: Use the SA911E, Snap-on® Tool HPC10 or equivalent, to remove the hose clamps.

• | Upper radiator hose at the cylinder head outlet

• | Deaeration hose at the intake manifold

• | Heater hose at the intake manifold or front of dash

Caution: Catch leaking fuel in a container whenever fittings are loosened or lines are disconnected.

10. Disconnect the fuel line.

10.1. | Fuel pressure can be bled into an approved container using the SA9127E .

10.2. | Remove the attachment bolt that clamps fuel lines to the intake manifold support brace.

10.3. | Disconnect the fuel supply line to the fuel rail.

10.4. | Remove the upper intake manifold support bracket bolt.

Important: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.

11. Unclip the lower splash shield attachments and place a 1 in. x 1 in. x 2 in. long block of wood between the torque strut and cradle.
12. Remove the 3 right-hand, upper engine torque axis mount to front cover nuts and the 2 mounts to midrail bracket nuts, allowing the powertrain to rest on the block of wood.

Important: The accessory drive belt idler pulley must be removed to allow the front cover to be removed and replaced in the vehicle.

13. Remove the accessory drive belt and tensioner. It is not necessary to remove the water pump pulley.

Important: Cover the camshaft area whenever repairs are not being performed to prevent foreign debris from entering the engine.

Important: Inspect the 8 cam cover silicone isolators for cracks. Replace the isolators if deterioration exists.

14. Remove the camshaft cover assembly.

Important: It is not necessary to remove the water pump pulley.

16. Remove the 5 power steering pump bracket attachment bolts, if equipped, and position the pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold. Refer to Engine Drive Belt and Accessories.

Important: The rear compressor bracket center hole is slotted for ease of compressor removal and installation.

Important: It is not necessary to discharge the A/C system.

17. Remove the 3 A/C compressor front bracket bolts, if equipped, attached to the cylinder head and block. The rear bracket bolts can be removed from the compressor or bracket attachment to the block and head.
18. Tie the compressor assembly to the vehicle front support bar.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

19. Jack or raise the vehicle on a hoist.
20. Drain the engine oil.
21. Remove the right wheel and splash shield.
22. Remove the intake manifold support brace bolt attached to the intake manifold located next to the generator.

Important: Puller jaw slots are cast into damper/pulley assembly for removal with a small 3 jaw puller if required.

23. Remove the front damper/pulley assembly. Hold the damper with a strap wrench or use a 3/4 in. square x 12 in. long piece of wood wedged between the damper spoke and rear, lower side of the front cover when removing the bolt.
24. Disconnect the exhaust pipe from the exhaust manifold.
25. Remove the 3 nuts from the flange.
26. Remove the front cover assembly.

| Important: Install the SA9104E with the flat side toward the sprocket. Failure to hold the crankshaft timing sprocket in place will cause timing chain guide damage. This tool also aligns the oil pump gerotor during front cover installation. After the front cover assembly is loosened and moved approximately 25.4 mm (1 in) from the engine, the crankshaft timing gear service tool should be removed.

25.1. | Install the SA9104E to make sure the front crankshaft timing sprocket is held firmly in place.

25.2. | Remove the 4 front oil pan bolts.

25.3. | Use the SA9123E to cut the oil pan seal away from the front cover.

25.4. | Spray the 2 dowel pin holes, upper left-hand and lower right-hand side of the cover, in the cover with penetrating oil to facilitate cover removal off the dowel pins.

| Important: One front cover assembly attachment bolt is located under the torque axis mount flange, above the accessory drive belt pulley.

25.5. | Remove the front cover bolts.

| Important: The front cover assembly can be removed from under the hood or through the wheel well.

| Important: Cover the front of the engine with a shop towel to prevent debris entry into oil gallery openings and the pan.

25.6. | Using a screwdriver, pry the front cover away from the cylinder block using the pry location tabs provided.

Important: Position the crankshaft 90 degrees off top dead center to make sure the pistons will not contact the valves upon assembly.

27. Rotate the crankshaft clockwise, viewed from the crankshaft accessory belt end, so the timing mark on the crankshaft sprocket and key way align with the main bearing cap split line.

Caution: The camshafts can rotate during timing chain and sprocket removal. Do not place fingers or tools between the camshaft sprocket and chain during removal or assembly.

28. Remove the timing chain tensioner, guides, camshaft sprockets, and chain. Use a 24 mm wrench to hold the camshaft when removing the sprocket bolts.

Important: Camshaft bearing caps are marked for proper installation.

29. Uniformly remove the camshaft bearing cap attachment bolts and caps.
30. Remove each camshaft.
31. Remove the lash adjuster and rocker arms. Keep them in order.

Notice: Only use a six point socket to remove the cylinder head bolts. A 12 point socket will round off the bolt heads.

Important: Head warpage or cracking could result from removing the bolts out of order or when the cylinder is hot.

32. Uniformly loosen and remove the 10 head bolts in several passes, in the following sequence.

Specifications
Intake Side: 3, 7, 10, 6, 2

Specifications
Exhaust Side: 4, 8, 9, 5, 1

Notice: Be careful not to damage the aluminum the aluminum cylinder head and block gasket sealing surfaces when removing the cylinder head or during cleaning.

33. Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks or a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block bosses.