Engine Mechanical

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ENGINE MECHANICAL
Engine
CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

REMOVAL & INSTALLATION
In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system or "remove the radiator. In most instances, a detailed removal procedure can be found elsewhere in this manual. It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. !areful observation and common sense are the best possible approaches to any repair procedure. "emoval and installation of the engine can be made easier if you follow these basic points#

• • • • •

If you have to drain any of the fluid ! u e a uita"le #ontainer$ Al%ay tag any %ire or ho e and! if &o i"le! the #o'&onent they #a'e fro' "efore di #onne#ting the'$ (e#au e there are o 'any "olt and fa tener involved! tore and la"el the retainer fro' #o'&onent e&arately in 'uffin &an ! )ar or #offee #an $ Thi %ill &revent #onfu ion during in tallation$ After un"olting the tran 'i ion or tran a*le! al%ay 'a+e ure it i &ro&erly u&&orted$ If it i ne#e ary to di #onne#t the air #onditioning y te'! have thi ervi#e &erfor'ed "y a ,ualified te#hni#ian u ing a re#overy-re#y#ling tation$ If the y te' doe not have to "e di #onne#ted! un"olt the #o'&re or and et it a ide$ .hen un"olting the engine 'ount ! al%ay 'a+e ure the engine i &ro&erly u&&orted$ .hen re'oving the engine! 'a+e ure that any lifting devi#e are &ro&erly atta#hed to the engine$ It i re#o''ended that if your engine i u&&lied %ith lifting hoo+ ! your lifting a&&aratu "e atta#hed to the'$ Lift the engine fro' it #o'&art'ent lo%ly! #he#+ing that no ho e ! %ire or other #o'&onent are till #onne#ted$ After the engine i #lear of the #o'&art'ent! &la#e it on an engine tand or %or+"en#h$ After the engine ha "een re'oved! you #an &erfor' a &artial or full teardo%n of the engine u ing the &ro#edure outlined in thi 'anual$ 0ro&erly relieve the fuel y te' &re ure$ 2i #onne#t the "attery #a"le fro' the "attery! negative #a"le fir t$



• • •

/$ 1$

3$ 6$ 7$ 8$ 9$ :$ ;$ /<$ //$ /1$ /3$ /6$ /7$ /8$ /9$ /:$ /;$ 1<$ 1/$ 11$ 13$ 16$

17$ 18$ 19$ 1:$ 1;$ 3<$ 3/$ 31$ 33$ 36$ 37$ 38$ 39$ 3:$ 3;$

6<$ 6/$ 61$ 63$ 66$

2eta#h the fuel line4to4fuel rail ,ui#+4di #onne#t fitting "y ,uee5ing the retainer ta" together and &ulling "a#+ on the fitting$ S#ri"e the hood hinge outline on the hood and re'ove the hood$ Re'ove the %i&er ar' and "lade a e'"lie $ Re'ove the #o%l #over fro' the vehi#le$ 2eta#h the &o itive lo#+ on the %i&er unit ele#tri#al #onne#tor$ 2eta#h the %i&er unit ele#tri#al #onne#tor fro' the engine #o'&art'ent %iring harne $ 2i #onne#t the %ind hield %a her ho e fro' the ho e #ou&ling in ide the %i&er unit$ Re'ove the drain tu"e fro' the "otto' of the %i&er unit$ Re'ove the ound a" or"er fro' the end of the %i&er unit$ Re'ove the atta#hing nut e#uring the %i&er unit to the lo%er %ind hield fen#e$ Re'ove the atta#hing "olt e#uring the %i&er unit to the da h &anel$ Rai e the %i&er unit fro' the %eld4 tud on the lo%er %ind hield fen#e and re'ove the %i&er unit fro' the vehi#le$ Re'ove the air #leaner a e'"ly and related ho e $ Re'ove the "attery #over! "attery! "attery tray and integral va#uu' re ervoir fro' the vehi#le$ If e,ui&&ed! "lo#+ off the rear heater to the rear heater unit$ 2rain the #ooling y te'$ Re'ove the u&&er and lo%er radiator ho e fro' the radiator$ 2i #onne#t and &lug the heater ho e fro' the engine$ Re'ove the radiator and #ooling fan a e'"ly$ 2i #onne#t the tran a*le hift lin+age$ 2i #onne#t the throttle "ody lin+age and all va#uu' ho e to the throttle "ody$ Re'ove a##e ory drive "elt $ Re'ove the air #onditioner #o'&re or fro' the engine and 'ounting "ra#+et $ =ee& the A-C #o'&re or ho e #onne#ted$ 0o ition the a e'"ly a ide and e#ure out of the %ay$ 2eta#h the %iring harne #onne#tor to the alternator$ Re'ove the alternator$ Rai e and afely u&&ort the vehi#le$ Re'ove the right and left half haft a e'"lie $ 2i #onne#t the tarter 'otor %iring and re'ove the tarter 'otor$ 2rain the engine oil and re'ove the oil filter$ Re'ove the right and left fender inner &la h hield $ 2i #onne#t the e*hau t &i&e fro' the e*hau t 'anifold$ Re'ove the front 'otor 'ount and 'ount "ra#+et a an a e'"ly$ Re'ove the rear tran a*le 'otor 'ount and "ra#+et$ Re'ove the &o%er teering &u'& and 'ounting "ra#+et a e'"ly fro' the engine$ 2eta#h! la"el and re'ove the %iring harne and #onne#tor fro' the front of the engine$ Re'ove "ending "ra#e $ Re'ove the tran a*le #a e in &e#tion #over$ Mar+ the fle*&late4to4tor,ue #onverter lo#ation$ Re'ove the "olt that 'ount the #onverter to the fle*&late$ Atta#h a 'all C4 #la'& to the front "otto' of the #onverter hou ing to &revent the #onverter fro' falling out of the tran a*le! if ne#e ary$ Lo%er the vehi#le to the ground$ 2i #onne#t the engine ground tra& $ Atta#h an engine lifting hoi t to the engine$ Re'ove the right engine 'ount a e'"ly and left tran a*le 'ount through"olt$ > ing the engine hoi t! rai e the engine and tran a*le a e'"ly lo%ly out of the vehi#le$ Se&arate the engine and tran a*le$ Se#ure the engine on an engine tand$

To install: 67$ Atta#h the tran a*le to the engine a e'"ly$

68$ .ith the hoi t atta#hed to the engine-tran a*le a e'"ly! lo%er the engine-tran a*le into the engine #o'&art'ent$ 69$ Align the engine and tran a*le 'otor 'ount to their atta#hing &oint $ In tall the right engine and left tran a*le 'ount "olt $ 6:$ Re'ove the engine hoi t$ 6;$ In tall "ending "ra#e $ 7<$ In tall the alternator$ 7/$ In tall and reatta#h the %iring harne #onne#tor on the front of the engine$ 71$ In tall the air #onditioning #o'&re or to the engine$ 73$ In tall the &o%er teering &u'& and 'ounting "ra#+et to the engine$ 76$ In tall a##e ory drive "elt and ad)u t to the &ro&er ten ion! if ne#e ary$ 77$ Rai e and afely u&&ort the vehi#le$ 78$ Re'ove the C4#la'& fro' the tor,ue #onverter hou ing! if utili5ed$ 79$ Align the fle*&late and tor,ue #onverter %ith the 'ar+ 'ade &reviou ly$ 7:$ In tall the #onverter4to4fle*&late 'ounting "olt $ Tighten the' to 77 ft$ l" $ ?97 N'@$ 7;$ In tall the tran a*le #a e lo%er in &e#tion #over$ 8<$ In tall right and left half haft a e'"lie $ 8/$ In tall the engine and tran a*le 'ount and "ra#+et a e'"lie $ 81$ In tall the e*hau t y te' to the e*hau t 'anifold $ 83$ In tall the left and right fender inner &la h hield $ 86$ In tall the tarter a e'"ly and re#onne#t the tarter 'otor %iring$ 87$ Re#onne#t the auto'ati# tran a*le hift lin+age$ 88$ Lo%er the vehi#le$ 89$ Reatta#h the fuel line ,ui#+4di #onne#t fitting to the fuel rail$ 8:$ Re#onne#t the #ooling y te' heater ho e to the engine$ 8;$ >n"lo#+ the heater ho e to the rear heater unit! if e,ui&&ed$ 9<$ Se#ure the engine ground tra& $ 9/$ Reatta#h the engine and throttle "ody va#uu' #onne#tion and %iring harne #onne#tor $ 91$ Re#onne#t the throttle "ody lin+age$ 93$ In tall the radiator! #ooling fan and hroud a e'"ly$ 96$ Re#onne#t the u&&er and lo%er radiator ho e $ 97$ In tall the "attery tray! "attery and "attery #over into the vehi#le$ 98$ In tall the air #leaner a e'"ly and ho e $ 99$ In tall a ne% engine oil filter$ Aill the #ran+#a e to the &ro&er oil level %ith the #orre#t ty&e of #lean engine oil$ 9:$ Refill the #ooling y te' to the &ro&er level %ith a 7<-7< 'i*ture of #lean ethylene gly#ol antifree5e and %ater$ 9;$ In tall the %i&er unit into the vehi#le engine #o'&art'ent! 'a+ing ure the %i&er unit i in talled &ro&erly over the %eld4 tud on the lo%er %ind hield fen#e$ In tall and tighten the atta#hing nut to the %eld4 tud $ :<$ In tall and tighten the atta#hing "olt e#uring the %i&er unit to the da h &anel$ :/$ In tall the ound a" or"er to ea#h end of the %i&er unit$ :1$ In tall the drain tu"e to the "otto' of the %i&er unit and re#onne#t the %ind hield %a her ho e to the ho e #ou&ling in ide the %i&er unit$ :3$ Reatta#h the %i&er unit %iring #onne#tor to the engine %iring harne $ :6$ 0la#e the #o%l #over onto the vehi#le$ Re#onne#t the right ide %ind hield %a her ho e to the right %a her no55le lo#ated on the under ide of the #o%l #over$ :7$ Engage the retainer that e#ure the #o%l #over to the front fender edge$ :8$ In tall and tighten the %ing nut that e#ure the front of the #o%l #over to the %i&er 'odule$ :9$ Engage the ,uarter turn fa tener that e#ure the outer end of the #o%l #over to the %i&er 'odule$

::$ In tall and tighten the "olt that hold the lo%er area of the #o%l #over to the %i&er 'odule$ :;$ Re#onne#t the &o itive "attery #a"le! then the negative "attery #a"le and verify that the %i&er 'otor and %i&er lin+age are in the 0AR= &o ition$ ;<$ In tall the %i&er ar' in the #orre#t &o ition over the %i&er ar' &ivot$ Align the %i&er ar' &o ition a follo% B /$ Left ar' hould "e no #lo er than 1$7 in$ ?87''@ fro' the lo%er edge of the %ind hield$ 1$ Right ar' hould "e no #lo er than /$7 in$ ?6<''@ fro' the lo%er edge of the %ind hield$ ;/$ In tall the %i&er ar'4to4%i&er ar' &ivot retaining nut and tighten to 18 ft$ l" $ ?37 N'@$ ;1$ 0u h do%n the %i&er ar' #a& #over and engage the #li& that e#ure the out ide end of the #over to the %i&er ar'$ ;3$ O&erate the %ind hield %i&er and en ure they %or+ and &ar+ &ro&erly$ ;6$ Ad)u t lin+age $ ;7$ In tall the hood$ ;8$ En ure all ele#tri#al #onne#tion ! #a"le ! ho e ! va#uu' and fuel line have "een atta#hed$ ;9$ Start the engine and run until nor'al o&erating te'&erature i indi#ated$ Che#+ for lea+ $ Road te t the vehi#le$

Ro#+er Ar' ?Valve@ Cover
REMOVAL & INSTALLATION
1$6L Engine

$alve cover tightening se%uence&'.() engine Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ La"el and di #onne#t the &ar+ &lug %ire $ Re'ove the ignition #oil &a#+! a de #ri"ed in Se#tion 1$ Re'ove the ground tra& fro' the valve #over$ 2i #onne#t the 0CV and "reather ho e $ Re'ove the valve #over retaining "olt $ Re'ove the valve #over fro' the engine$

To install: Before installing the valve cover, clean the valve cover-to-cylinder head mating surfaces. Inspect the spark plug well seals for swelling or cracking, and replace if necessary.

9$ :$

In tall the ne% valve #over ga +et$ A&&ly MO0ARC Sili#one Ru""er Adhe ive Sealant or e,uivalent at the #a' haft #a& #orner and at the to& edge of the /-1 round eal$ 0la#e the valve #over into &o ition on to& of the #ylinder head$ Tighten the valve #over retaining "olt in the #orre#t e,uen#e a illu trated$ > e the 34 te& tightening e,uen#e a follo% B /$ 6< in#h l" $ ?6$7 N'@ 1$ :< in#h l" $ ?; N'@ 3$ /<7 in#h l" $ ?/1 N'@ Conne#t the 0CV and "reather ho e $ In tall the #oil &a#+ a e'"ly! a de #ri"ed in Se#tion 1$ Conne#t the &ar+ &lug %ire $ Aollo% the la"el to a ure #orre#t &lug %ire #onne#tion $ Atta#h the ground tra& to the valve #over$ Conne#t the negative "attery #a"le$

;$

/<$ //$ /1$ /3$ /6$

3$<L Engine

$alve cover detail&*.+) engine Cli#+ to enlarge /$ 1$ 3$ 0ro&erly relieve the fuel y te' &re ure$

6$ 7$ 8$

9$ :$

2i #onne#t the negative "attery #a"le$ 2rain the #ooling y te'$ Re'ove the a##e ory drive "elt and the air #onditioning #o'&re or fro' it 'ount and u&&ort it a ide$ Re'ove the alternator and &o%er teering &u'& fro' the "ra#+et and 'ove the' a ide$ Rai e the vehi#le and u&&ort afely$ Re'ove the right front %heel and the right inner &la h hield$ Re'ove the #ran+ haft &ulley and the tor ional da'&er$ Lo%er the vehi#le$ > ing a floor )a#+ and a "lo#+ of %ood &o itioned under the oil &an! rai e the engine lightly$ Re'ove the engine 'ount "ra#+et fro' the ti'ing #over end of the engine$ Re'ove the ti'ing "elt #over $ Re'ove the ti'ing "elt a de #ri"ed in the unit re&air e#tion in the "eginning of thi 'anual$

;$

Hold the #a' haft &ro#+et u ing a uita"le tool and re'ove the #a' haft &ro#+et retaining "olt$ Re'ove the &ro#+et and the inner ti'ing "elt #over ?left "an+@ and-or alternator "ra#+et ?right "an+@$ /<$ La"el and di #onne#t the &ar+ &lug %ire fro' the &ar+ &lug $ //$ If re'oving the left ?front@ #ylinder head! re'ove the di tri"utor #a& and &ar+ &lug %ire $ Mar+ the &o ition of the rotor and di tri"utor in relation to the #ylinder head and re'ove the di tri"utor$ Re'ove the di tri"utor drive ada&ter$ /1$ Re'ove the valve #over$ To install: /3$ In tall the valve #over$ /6$ In tall the inner ti'ing "elt #over ?left "an+@ and-or alternator "ra#+et ?right "an+@$ /7$ 0o ition the #a' haft &ro#+et$ Hold the &ro#+et u ing a uita"le tool and in tall the #a' haft &ro#+et "olt$ Tighten the "olt to 9< ft$ l" $ ?;7 N'@$ Be sure the timing elt sprocket timing marks are aligned.

/8$ If re'oved! in tall the di tri"utor! aligning the 'ar+ 'ade during re'oval$ In tall the di tri"utor #a& and &ar+ &lug %ire $ /9$ In tall the ti'ing "elt$ /:$ In tall the ti'ing "elt #over and the engine u&&ort "ra#+et$ /;$ In tall the tor ional da'&er and tighten the "olt to //1 ft$ l" $ ?/7/ N'@$ In tall the #ran+ haft &ulley $ 1<$ In tall the inner &la h hield and the right front %heel$ Tighten the %heel lug nut to ;7 ft$ l" $ ?/1; N'@$ Lo%er the vehi#le$ 1/$ In tall the alternator! &o%er teering &u'& and air #onditioning #o'&re or$ 11$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 13$ Refill the #ooling y te'$ Sin#e #oolant #an #onta'inate the engine oil %hen a #ylinder head i re'oved! an oil and filter #hange i re#o''ended$ 16$ Re#onne#t the negative "attery #a"le$ 17$ Start the engine and #he#+ for lea+ $ Che#+ the ignition ti'ing$

3$3L and 3$:L Engine

$alve cover detail&*.* and *.,) engines /$ 1$ 3$ 6$ 7$ 8$ 0ro&erly relieve the fuel y te' &re ure$

2i #onne#t the negative "attery #a"le and drain the #ooling y te'$ Re'ove the inta+e 'anifold %ith the throttle "ody$ 2i #onne#t the #oil %ire ! ending unit %ire! heater ho e and "y&a ho e$ Re'ove the #lo ed ventilation y te'! eva&oration #ontrol y te' and #ylinder head #over? @$ Clean all ga +et 'ating urfa#e $

To install: 9$ In tall the valve #over %ith a ne% ga +et$ Tighten the valve #over "olt to /<7 in#h l" $ ?/1 N'@$ In tall the e*hau t 'anifold #ro over &i&e$ Tighten the "olt to 1< ft$ l" $ ?19 N'@ and the nut to /7 ft$ l" $ ?1< N'@$

:$ In tall the #lo ed ventilation y te' and the eva&oration #ontrol y te'$ ;$ Re#onne#t the #oil %ire ! ending unit %ire! heater ho e and "y&a ho e$ /<$ En ure all %iring #onne#tion ! #a"le ! ho e ! va#uu' and fuel line have "een reatta#hed$ //$ Refill the #ooling y te' to the #orre#t level$ /1$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $

Ro#+er Ar'-Shaft
REMOVAL & INSTALLATION
3$<L Engine
The roc-er arms and shafts are retained by the camshaft bearing journal caps. Four shafts are used, one for each inta-e and exhaust roc-er arm assembly on each cylinder head. The hollow shafts provide a duct for lubricating oil from the cylinder head to the valve mechanisms. The roc-er arms are lightweight die&cast with roller&type followers operating against the

camshaft. The valve actuating end of the roc-er arms are machined to retain hydraulic lash adjusters, eliminating valve lash adjustment.

.xploded view of the roc-er arms and shafts. Install cap /o. ' in the correct position on the oil hole&*.+) engine Cli#+ to enlarge /$ 1$ 3$ 6$ 2i #onne#t the negative "attery #a"le$ 2i #onne#t and la"el the &ar+ &lug %ire $ Re'ove the air #leaner a e'"ly$ Re'ove the a##e ory drive "elt ! and deta#h the va#uu' #onne#tion $ Re'ove the valve #over$ (efore re'oving the ro#+er ar' haft a e'"ly! a fun#tion #he#+ #an "e 'ade of the auto la h ad)u ter $ > e the follo%ing &ro#edureB

The auto lash ad!usters are precision units installed in machined openings in the valve actuating ends of the rocker arms. "o not disassem le the auto lash ad!usters. /$ 1$ 3$ Che#+ the ad)u ter for free4&lay "y in erting a 'all %ire through the air "leed hole in the ro#+er ar'$ VERD LIGHTLD &u h the auto ad)u ter #he#+ "all do%n$ .hile lightly holding the #he#+ "all do%n! 'ove the ro#+er ar' u& and do%n to #he#+ for free4&lay$ If there i no free4&lay! re&la#e the ad)u ter$ In tall La h Ad)u ter Retainer M2;;:663 or e,uivalent! on the ro#+er ar' $ Loo en all the #a' haft "earing #a& "olt $ 2o not re'ove the "olt fro' "earing #a& $ Re'ove the ro#+er ar' ! ro#+er haft and "earing #a& a an a e'"ly$ Re'ove the "olt fro' the #a' haft "earing #a& and re'ove the ro#+er haft and ar' $ =ee& all &art in order$ Note the %ay the ro#+er haft! ro#+er ar' ! "earing #a& and &ring are 'ounted$ The ro#+er ar' haft on the inta+e ide ha a 3'' dia'eter oil &a age hole fro' the #ylinder head$ The e*hau t ide doe not have thi oil &a age$

7$ 8$

9$

0e sure to install the roc-er arm shaft with the oil hole on the inta-e side of the head&*.+) engine :$ In &e#t the ro#+er ar' 'ounting area and ro#+er for da'age$ Re&la#e if %orn or heavily da'aged$ Che#+ oil &a age for #logging and #lean! if ne#e ary$

To install: ;$ Lu"ri#ate the ro#+er ar' and haft %ith #lean engine oil &rior to in tallation$

/<$ Identify No$ / "earing #a&! ?No$ / and No$ 6 #a& are i'ilar@$ In tall the ro#+er haft into the "earing #a& %ith not#he in &ro&er &o ition$ In ert the atta#hing "olt to retain a e'"ly$ //$ In tall the ro#+er ar' ! &ring and "earing #a& on haft in nu'eri#al e,uen#e$ /1$ Align the #a' haft "earing #a& %ith arro% ?de&ending on the #ylinder "an+@$ /3$ In tall the "olt in No$ 6 #a& to retain a e'"ly$ /6$ A&&ly ili#one ru""er ealant at "earing #a& end $

1pply silicone sealant to the cylinder head in the areas indicated&*.+) engine

/7$ In tall the ro#+er ar' haft a

e'"ly$

Be sure the arrow mark on the earing caps and the arrow mark on the cylinder heads are in the same direction. The direction of arrow marks on the front and rear assem lies are opposite to each other. /8$ Tighten the "earing #a& "olt to :7 in#h l" $ ?/< N'@ in the follo%ing orderB /$ No$ 3 #a& 1$ No$ 1 #a& 3$ No$ / #a& 6$ No$ 6 #a& Re&eat the &reviou te&! in#rea ing tor,ue to /:< in#h l" $ ?1< N'@$ Re'ove the la h ad)u ter retainer $ In tall the di tri"utor drive ada&ter! if re'oved$ In tall the valve #over$ Tighten the valve #over retaining "olt to :: in#h l" $ ?/< N'@$ Reatta#h all va#uu' #onne#tion $ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ In tall air #leaner a e'"ly$ Re#onne#t the &ar+ &lug %ire $ Re#onne#t the negative "attery #a"le$ Run the engine and #he#+ for lea+ and &ro&er engine o&eration$

/9$ /:$ /;$ 1<$ 1/$ 11$ 13$

3$3L and 3$:L Engine
/$ 1$ 3$ 6$ 7$ 8$ 9$ 2i #onne#t the negative "attery #a"le$ Re'ove the u&&er inta+e 'anifold a e'"ly$ 2i #onne#t and la"el the &ar+ &lug %ire $ 2i #onne#t the #lo ed ventilation y te'$ Re'ove the ro#+er ar' #over and ga +et$ Re'ove the four ro#+er haft retaining "olt and retainer $ Re'ove the ro#+er ar' and haft a e'"ly$ If di a e'"ling the ro#+er haft! "e ure to identify all #o'&onent o they #an "e rein talled in their original lo#ation $

"oc-er arms and shaft assembly&*.*) and *.,) engines :$ In &e#t the ro#+er ar' and haft for %ear and-or da'ageE re&la#e #o'&onent a ne#e ary$ ;$ If ne#e ary! re'ove the &u hrod $ Identify ea#h &u hrod a it i re'oved! o it #an "e rein talled in it original lo#ation$ /<$ In &e#t the &u hrod for %ear and-or da'age$ Roll ea#h &u hrod on a flat urfa#e to #he#+ for a "ent #ondition$ Re&la#e &u hrod a ne#e ary$ To install:

//$ If re'oved! in tall the &u hrod in their &ro&er lo#ation $ Lu"ri#ate the &u hrod end %ith #lean engine oil! &rior to in tallation$ (e ure the &u hrod are eated in the lifter $ /1$ Lu"ri#ate the ro#+er ar' and haft %ith #lean engine oil! &rior to in tallation$ /3$ If the ro#+er haft %a di a e'"led! rea e'"le 'a+ing ure all #o'&onent are in talled in their original lo#ation $ The rocker arm shaft should e tightened slowly, starting with the center olts. #llow $% minutes, for tappet leed down after installation, efore engine operation. /6$ In tall the ro#+er ar' and haft a e'"ly! u ing the four retainer $ (e ure the &u hrod are eated in the ro#+er ar' $ Tighten the retaining "olt to 17< in#h l" $ ?1: N'@$ /7$ In tall the ro#+er #over %ith a ne% ga +et$ (e ure the #over ga +et 'ating urfa#e i #lean and 'ooth$ Tighten the ro#+er #over retaining "olt to /<7 in#h l" $ ?/1 N'@$ /8$ In tall the #ran+#a e ventilation #o'&onent and re#onne#t the &ar+ &lug %ire $ /9$ In tall the u&&er inta+e 'anifold a e'"ly$ Re#onne#t the negative "attery #a"le$ /:$ Run the engine and #he#+ for lea+ and &ro&er engine o&eration$

Ther'o tat
REMOVAL & INSTALLATION
1$6L Engine
/$ 1$ 2i #onne#t the negative "attery #a"le$ 0la#e a large drain &an under the radiator drain &lug$ Allo% the #ooling y te' to uffi#iently #ool do%n "efore o&ening the drain &lug to avoid &er onal in)ury$ 2rain the #oolant to "elo% the ther'o tat level$ 2i #onne#t the u&&er radiator ho e at the ther'o tat hou ing$ Re'ove the ther'o tat hou ing "olt and #oolant outlet #onne#tor of the ther'o tat hou ing$ Re'ove the ther'o tat a e'"ly fro' the vehi#le and di #ard$ 2i #ard the old ther'o tat ga +et$

3$ 6$ 7$

Thermostat installation&'.() engine To install: 8$ 9$ Clean all ga +et 'ating urfa#e $ In tall the ne% ther'o tat in the #orre#t &o ition$ If e,ui&&ed! align the air "leed valve on to& of ther'o tat to the vent re#e in the %ater "o* ?engine ide@ of the ther'o tat hou ing$ 2i& the ne% ne% ga +et in #lean %ater and in tall on the %ater "o* urfa#e of the ther'o tat hou ing$ In tall the ther'o tat hou ing over the ga +et and ther'o tat! 'a+ing ure the ther'o tat i in #orre#t &o ition$ In tall the ther'o tat hou ing "olt and tor,ue to 1< ft$ l" $ ?1: N'@$ Re#onne#t the radiator ho e$ Tighten the radiator ho e #la'&$ Conne#t the negative "attery #a"le$ Aill and "leed the engine #ooling y te'$ 0re ure te t for lea+ $

:$ ;$ /<$ //$ /1$ /3$ /6$

3$<L! 3$3L and 3$:L Engine
/$ 1$ 3$ 6$ 2i #onne#t the negative "attery #a"le$ 0la#e a drain &an under the radiator drain and drain the #ooling y te' to )u t "elo% the ther'o tat level$ Clo e the drain$ Re'ove the u&&er radiator ho e fro' the ther'o tat hou ing! then re'ove the hou ing$ Re'ove the ther'o tat and di #ard the ga +et$

Thermostat installation detail&*.+) engine Cli#+ to enlarge

Thermostat installation detail&*.*) and *.,) engines Cli#+ to enlarge

To install: 7$ 8$ 9$ Clean the hou ing 'ating urfa#e $ 2i& the ne% ga +et in #lean %ater and &la#e it on the %ater "o* urfa#e$ Center the ther'o tat on the ga +et! in the %ater "o*$

"emove the radiator hose from the waternec- by loosening the hose clamp ... :$ Ma+e #ertain the "olt thread are #lean$ Threaded "olt hole e*&o ed to #oolant are u")e#t to #orro ion and hould "e #leaned %ith a 'all %ire "ru h or #orre#t i5e thread4#utting ta&$ In tall the hou ing! 'a+ing ure the ther'o tat i till in the re#e ! and tighten the retaining "olt to /<7 in#h l" $ ?/1 N'@ for 3$<L engine or to 1/ ft$ l" $ ?1: N'@ for 3$3L and 3$:L engine $ Re#onne#t the u&&er radiator ho e and tighten the ho e #la'&$ ;$ Conne#t the negative "attery #a"le$ /<$ Aill and "leed the engine #ooling y te' %ith a #lean 7<-7< 'i*ture of ethylene gly#ol antifree5e and %ater$

)ift the waternec- housing off of the lower inta-e manifold, then ... ... remove the thermostat out of its mounting flange //$ Ma+e ure the radiator i full and tart the vehi#le$

CAUTION
2o not remove the radiator cap once the vehicle is warm. !oolant is under pressure and may cause scalding or personal injury. /1$ Run the vehi#le until the ther'o tat o&en $ Che#+ the #oolant level in the overflo% tan+ and fill if ne#e ary$ /3$ 0re ure te t for lea+ $

3a-e sure to clean the waternec- before installation

Inta+e Manifold
REMOVAL & INSTALLATION CAUTION
The fuel injection system remains under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1$6L Engine

)ower inta-e manifold mounting points&'.() engine Cli#+ to enlarge The '.() engine inta-e manifold is a long branch design made of cast aluminum. It is attached to the cylinder head with eight fasteners. /$ 1$ 3$ 6$ 0ro&erly relieve the fuel y te' &re ure$

7$ 8$ 9$ :$

;$ /<$ //$ /1$ /3$

2i #onne#t the negative "attery #a"le$ 2i #onne#t the air #leaner inlet ho e fro' the throttle "ody$ 2i #onne#t the throttle #a"le and &eed #ontrol #a"le ?if e,ui&&ed@ fro' the throttle lever and #a"le "ra#+et$ The #a"le? @ #an "e re'oved fro' the "ra#+et "y #o'&re ing the retaining ta" $ 2eta#h the Idle Air Control ?IAC@ 'otor and Throttle 0o ition Sen or ?T0S@ %iring #onne#tor on the throttle "ody$ 2i #onne#t the va#uu' ho e fro' the inta+e &lenu' fitting $ 2eta#h the ele#tri#al #onne#tor fro' the Manifold A" olute 0re ure ?MA0@ and Inta+e Air Te'&erature ?IAT@ en or $ 2eta#h the fuel line ,ui#+4di #onne#t fitting fro' the #ha i fuel line tu"e "y ,uee5ing the retainer ta" together and &ulling the fitting a e'"ly fro' the fuel tu"e ni&&le$ The retainer %ill re'ain on the fuel tu"e$ > e ho& to%el to #at#h any &illed fuel$ Re'ove the EGR tu"e and ga +et at the EGR valve$ 2rain the #ooling y te' and re'ove the a##e ory drive "elt$ If ne#e ary! re'ove the alternator 'ounting "ra#+et$ Re'ove the 'ounting "olt that e#ure the "otto' of the inta+e u&&ort "ra#+et$ Re'ove the eight inta+e 'anifold fa tener and %a her $ Re'ove the inta+e 'anifold fro' the engine$

To install: /6$ Thoroughly #lean all &art $ Che#+ the 'ating urfa#e for #ra#+ or di tortion$ /7$ In tall a ne% inta+e 'anifold ga +et and &o ition the 'anifold on the #ylinder head$ In tall and tighten the fa tener to 1<< in#h l" $ ?13 N'@ tarting fro' the #enter and %or+ing out%ard in "oth dire#tion $ /8$ In tall the 'ounting "olt that e#ure the "otto' of the inta+e u&&ort "ra#+et! and in tall the alternator 'ounting "ra#+et ?if re'oved@$ /9$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ /:$ In tall the EGR ga +et and tu"e to the EGR valve$ /;$ In &e#t the ,ui#+4di #onne#t fitting for da'age and re&air a re,uired$ Lightly lu"e the fuel line tu"e %ith #lean 3<. engine oil$ Re#onne#t the fuel

1<$ 1/$ 11$ 13$ 16$ 17$ 18$ 19$ 1:$

ho e ,ui#+4di #onne#t fitting to the #ha i fuel tu"e$ 0u h the ,ui#+4 di #onne#t fitting onto the #ha i fuel tu"e until it #li#+ into &la#e$ Che#+ the #onne#tion "y &ulling on the fitting to in ure it i lo#+ed in &o ition$ Re#onne#t the MA0 and IAT air te'&erature en or %iring #onne#tor $ Re#onne#t the va#uu' ho e to the inta+e &lenu' fitting $ Reatta#h the IAC 'otor and T0S %iring #onne#tor $ In tall the throttle #a"le into the throttle #a"le "ra#+et$ (e ure to engage the retaining ta" $ Re#onne#t the throttle #a"le and &eed #ontrol #a"le ?if e,ui&&ed@ to the throttle lever$ In tall the air #leaner inlet ho e to the throttle "ody$ Refill the #ooling y te' %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater to the &ro&er level$ Re#onne#t the negative "attery #a"le$ Run the engine and #he#+ for lea+ and &ro&er o&eration$

3$<L Engine

*.+) inta-e and exhaust manifold exploded view Cli#+ to enlarge /$ 1$ 3$ 6$ 0ro&erly relieve the fuel y te' &re ure$

2i #onne#t the negative "attery #a"le$ 2rain the #ooling y te'$ Re'ove the air #leaner4to4throttle "ody ho e$

First, label and remove the 4!$ valve hose from the roc-er arm cover and valve ...

1fter removing the throttle body, disconnect any residual vacuum lines from the manifold plenum 7$ 8$ Re'ove the throttle #a"le and tran a*le +i#+do%n #a"le$ Re'ove the Auto'ati# Idle S&eed ?AIS@ 'otor and Throttle 0o ition Sen or ?T0S@ ele#tri#al #onne#tor fro' the throttle "ody$ 2eta#h the va#uu' #onne#tion fro' throttle "ody$ Re'ove the 0CV and "ra+e "oo ter ho e fro' the air inta+e &lenu'$ Re'ove the ignition #oil fro' the inta+e &lenu'$ Re'ove the EGR tu"e fro' the inta+e &lenu' ?if e,ui&&ed@$ Re'ove the ele#tri#al #onne#tion fro' the #oolant te'&erature en or$ Re'ove the va#uu' #onne#tion fro' the fuel &re ure regulator$ Re'ove the air inta+e #onne#tion fro' the air inta+e &lenu'$ Re'ove the fuel ho e4to4fuel rail #onne#tion $ Re'ove the air inta+e &lenu'4to4'anifold "olt ?:@! and re'ove the air inta+e &lenu' and ga +et$

9$ :$ ;$ /<$ //$ /1$ /3$

WARNING
5henever the air inta-e plenum is removed, cover the inta-e manifold properly to -eep objects from entering the cylinder head.

)oosen and remove the .6" tube flange&to&lower inta-e manifold mounting bolts ...

... and remove the .6" tube itself from the inta-e manifold

"emove and label the vacuum hose from the front of the upper inta-e manifold plenum ...

... then label and remove any electrical wires and connectors from the lower manifold /6$ La"el and di #onne#t the fuel in)e#tor %iring harne harne $ fro' the engine %iring

/7$ 2i #onne#t the va#uu' ho e fro' the fuel rail! then re'ove the &re ure regulator atta#hing "olt and re'ove the &re ure regulator fro' the rail$ /8$ Re'ove the fuel rail atta#hing "olt and re'ove the fuel rail$ /9$ Re'ove the radiator ho e fro' the ther'o tat hou ing and the heater ho e fro' the &i&e$ /:$ Re'ove the inta+e 'anifold atta#hing nut and %a her ! and re'ove the inta+e 'anifold$ /;$ Clean the ga +et 'aterial fro' the #ylinder head and 'anifold ga +et urfa#e$ Che#+ for #ra#+ or da'aged 'ounting urfa#e $ To install:

1<$ In tall a ne% ga +et on the inta+e urfa#e of the #ylinder head and in tall the inta+e 'anifold$ 1/$ In tall the inta+e 'anifold %a her and nut $ Tighten the inta+e 'anifold atta#hing nut ! in e,uen#e! to /7 ft$ l" $ ?1< N'@$

)oosen and remove the upper&to&lower manifold fasteners ...

... then lift the upper inta-e manifold plenum from the lower manifold

2isconnect the radiator&to&waternec- coolant hose from the waternec- and ...

... disconnect the smaller coolant hose from the water box 11$ Clean the in)e#tor and lu"ri#ate the in)e#tor O4ring %ith a dro& of #lean engine oil$ 13$ 0la#e the ti& of ea#h in)e#tor into their &ort $ 0u h the a e'"ly into &la#e until the in)e#tor are eated in their &ort $ 16$ In tall the fuel rail atta#hing "olt and tighten to //7 in#h l" $ ?/3 N'@$ 17$ In tall the fuel u&&ly and return tu"e hold4do%n "olt and the va#uu' #ro over tu"e hold4do%n "olt$ Tighten to ;7 in#h l" $ ?// N'@$ 18$ Conne#t the in)e#tor %iring harne to the engine %iring harne $ 19$ Re'ove the #overing fro' the inta+e 'anifold$ 1:$ 0o ition the inta+e 'anifold ga +et! "eaded ide u&! on the inta+e 'anifold$ 1;$ 0la#e the air inta+e &lenu' in &o ition$ In tall the atta#hing "olt and tighten! in e,uen#e! to //7 in#h l" $ ?/3 N'@$ 3<$ Conne#t the fuel line to the fuel rail$ Tighten the #la'& to /< in#h l" $ ?/ N'@$ 3/$ Conne#t the va#uu' ho e to the inta+e &lenu'$

31$ Conne#t the ele#tri#al #onne#tion to the #oolant te'&erature en or$ 33$ Conne#t the EGR tu"e flange to the inta+e &lenu' ?if e,ui&&ed@ and tighten to /7 ft$ l" $ ?1< N'@$ 36$ Re#onne#t the 0CV ho e and the "ra+e "oo ter u&&ly ho e to the inta+e &lenu'$ 37$ Re#onne#t the auto'ati# idle &eed #ontrol 'otor and T0S ele#tri#al #onne#tor $ 38$ Conne#t the throttle "ody va#uu' ho e and ele#tri#al #onne#tion $ 39$ In tall the throttle #a"le and tran a*le +i#+do%n lin+age$ 3:$ In tall the air inlet ho e a e'"ly$

)oosen and remove the relay brac-et&to&lower inta-e manifold attaching nut, ...

... unscrew the bolt and ...

... remove the relay and brac-et from the engine 3;$ In tall the radiator and heater ho e$ 6<$ Refill the #ooling y te' %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater to the &ro&er level$ 6/$ Re#onne#t the negative "attery #a"le$ An engine oil and filter #hange i re#o''ended$ 61$ Run the vehi#le until it rea#he o&erating te'&erature and #he#+ the #ooling y te'! fuel y te' and engine for fuel! oil or #oolant lea+ $

"emove the remaining lower inta-e manifold mounting bolts, then lift the manifold off of the engine

Tighten the inta-e manifold bolts in the correct se%uence to prevent vacuum lea-s&*.+) engine

Tighten the inta-e as shown&*.+) engine

3$3L and 3$:L Engine

7n *.*) and *.,) engines, there are mounting brac-ets behind the plenum /$ 1$ 3$ 6$ 7$ 8$ 0ro&erly relieve the fuel y te' &re ure$

2i #onne#t the negative "attery #a"le$ Re'ove the %i&er ar' and "lade a e'"lie $ Re'ove the #o%l #over fro' the vehi#le$ O&en the hood$ 2eta#h the &o itive lo#+ on the %i&er unit ele#tri#al #onne#tor$ 2eta#h the %i&er unit ele#tri#al #onne#tor fro' the engine #o'&art'ent %iring harne $ 9$ 2i #onne#t the %ind hield %a her ho e fro' the ho e #ou&ling in ide the %i&er unit$ :$ Re'ove the drain tu"e fro' the "otto' of the %i&er unit$ ;$ Re'ove the ound a" or"er fro' the end of the %i&er unit$ /<$ Re'ove the atta#hing nut e#uring the %i&er unit to the lo%er %ind hield fen#e$ //$ Re'ove the atta#hing "olt e#uring the %i&er unit to the da h &anel$ /1$ Rai e u& the %i&er unit fro' the fro' the %eld4 tud on the lo%er %ind hield fen#e and re'ove the %i&er unit fro' the vehi#le$

*.*) and *.,) plenum&to&manifold attachment detail

Inta-e manifold removal&*.*) and *.,) engines Cli#+ to enlarge /3$ 2rain the #ooling y te'$ /6$ If e,ui&&ed! re'ove the inta+e 'anifold #over$ /7$ 2i #onne#t the air inlet re onator4to4throttle "ody ho e a e'"ly$ /8$ 2i #onne#t the throttle #a"le and re'ove the %iring harne fro' the #a"le "ra#+et$ /9$ Re'ove the Auto'ati# Idle S&eed ?AIS@ 'otor and Throttle 0o ition Sen or ?T0S@ %iring #onne#tor fro' the throttle "ody$ /:$ Re'ove the va#uu' ho e harne fro' the throttle "ody$ /;$ Re'ove the 0CV and "ra+e "oo ter ho e fro' the air inta+e &lenu'$ 1<$ Re'ove the EGR tu"e flange and the va#uu' harne #onne#tor fro' the inta+e &lenu'$ 1/$ If e,ui&&ed! deta#h the #harge te'&erature en or ele#tri#al #onne#tor$ Re'ove the va#uu' harne #onne#tor fro' the inta+e &lenu'$ 11$ Re'ove the #ylinder head4to4inta+e &lenu' trut$ 13$ 2eta#h the MA0 en or %iring #onne#tor$ Re'ove the engine 'ounted ground tra&$ 16$ Re'ove the fuel ho e ,ui#+4di #onne#t fitting fro' the fuel rail "y &ulling "a#+ on the fitting %hile &u hing in the &la ti# ring$ Thi 'ay re,uire the u e of an o&en end %ren#h to &u h in the &la ti# ring$ (e ure to &lug the o&en fuel line to &revent y te' #onta'ination$ .ra& a ho& to%el around the fuel ho e to a" or" any fuel &ill$ 17$ Re'ove the 2IS #oil and the alternator "ra#+et to inta+e 'anifold "olt$ 18$ Re'ove the alternator %iring harne fro' the "a#+ of the u&&er inta+e 'anifold &lenu'$ 19$ Re'ove the atta#hing "olt and re'ove the u&&er inta+e 'anifold$ Cover the inta+e 'anifold o&ening to &revent foreign 'aterial fro' entering the engine$ 1:$ Re'ove the fuel tu"e retainer "ra#+et "olt and fuel rail atta#hing "olt $ S&read the retainer "ra#+et to allo% for #learan#e %hen re'oving the fuel tu"e$ 1;$ 2eta#h the #a' en or and #oolant te'&erature en or #onne#tor $ 3<$ Re'ove the in)e#tor %iring #li& fro' the inta+e 'anifold %ater tu"e$ 3/$ Re'ove the fuel rail$ (e #areful not to da'age the fuel in)e#tor O4ring $ 31$ Re'ove the u&&er radiator ho e! "y&a ho e and rear inta+e 'anifold ho e$ 33$ Re'ove the inta+e 'anifold "olt and re'ove the 'anifold fro' the engine$ 36$ Re'ove the inta+e 'anifold eal retaining "olt and re'ove the 'anifold ga +et$ 37$ Clean out any #logged end %ater &a age and fuel runner $ To install: 38$ Clean and dry all ga +et 'ating urfa#e $ 39$ 0la#e a "ead of a&&ro*i'ately /-6 in$ ?8''@ dia'eter of ili#one ealant onto ea#h of the four 'anifold4to4#ylinder head ga +et #orner $

CAUTION
The inta-e manifold gas-et is made of very thin material and could cause personal injury. 8andle with care. 3:$ Carefully in tall the inta+e 'anifold ga +et and tighten the end eal retainer "olt to /<7 in#h l" $ ?/1 N'@$ 3;$ In tall the inta+e 'anifold and eight retaining "olt and tighten to /< in#h l" $ ?/ N'@$ Then tighten the "olt ! in e,uen#e! to 1<< in#h l" $ ?11 N'@$ 6<$ .hen the "olt are tightened! in &e#t the eal to en ure that they have not "e#o'e di lodged$

6/$ Lu"ri#ate the in)e#tor O4ring %ith #lean oil to ea e in tallation$ 0ut the ti& of ea#h in)e#tor into it &ort and &la#e the fuel rail in &o ition$ In tall the fuel rail 'ounting "olt and tighten to 1<< in#h l" $ ?11 N'@$ 61$ In tall the fuel tu"e retaining "ra#+et "olt$ Tighten the "olt to 37 in#h l" $ ?6 N'@$ 63$ Conne#t the #a'! #oolant te'&erature and engine te'&erature en or if e,ui&&ed$ 66$ In tall the u&&er inta+e 'anifold %ith a ne% inta+e 'anifold ga +et$ In tall the "olt only finger4tight$ In tall the alternator "ra#+et to inta+e 'anifold "olt and the #ylinder head to inta+e 'anifold trut "olt $ Tighten the inta+e 'anifold 'ounting "olt to 17< in#h l" $ ?1: N'@ tarting fro' the 'iddle and %or+ing out%ard$ 67$ Tighten the alternator "ra#+et and #ylinder head4to4inta+e 'anifold trut "olt to 6< ft$ l" $ ?76 N'@$ 68$ Conne#t the alternator %iring harne to the alternator and to the rear of the inta+e 'anifold$ 69$ Re#onne#t the ground tra& and MA0 en or #onne#tor $ 6:$ Re#onne#t the inta+e &lenu' va#uu' harne $ 6;$ In tall a ne% ga +et and #onne#t the EGR tu"e to the inta+e 'anifold$ Tighten the retaining fa tener to 1<< in#h l" $ ?11 N'@$ 7<$ Cli& the %iring harne into the throttle #a"le "ra#+et hole$ Re#onne#t the Throttle 0o ition Sen or ?T0S@ and Auto'ati# Idle S&eed ?AIS@ #ontrol 'otor %iring #onne#tor $ 7/$ Re#onne#t the throttle "ody va#uu' harne and in tall the ignition #oil $ Tighten the ignition #oil fa tener to /<7 in#h l" $ ?/1 N'@$ 71$ Lightly lu"ri#ate the end of the fuel line %ith #lean! 3<. engine oil$ Re#onne#t the fuel ho e to the rail$ 0u h the fitting in until they #li#+ in &la#e$ 0ull "a#+ on the ,ui#+4di #onne#t fitting to en ure that the fuel line are e#urely lo#+ed in &la#e$ 73$ Re#onne#t the throttle #a"le$ 76$ Re#onne#t the fuel in)e#tor %iring harne $ 77$ In tall the air inlet re onator to throttle "ody ho e a e'"ly$ 78$ If e,ui&&ed! in tall the inta+e 'anifold #over$ 79$ In tall the %i&er unit into the vehi#le engine #o'&art'ent$ (e ure the %i&er unit i in talled &ro&erly over the %eld4 tud on the lo%er %ind hield fen#e$ In tall and tighten the atta#hing nut to the %eld4 tud $ 7:$ In tall and tighten the atta#hing "olt e#uring the %i&er unit to the da h &anel$ 7;$ In tall the ound a" or"er to ea#h end of the %i&er unit$ 8<$ In tall the drain tu"e to the "otto' of the %i&er unit and re#onne#t the %ind hield %a her ho e to the ho e #ou&ling in ide the %i&er unit$ 8/$ Re#onne#t the %i&er unit %iring #onne#tor to the engine %iring harne $ 81$ 0la#e the #o%l #over onto the vehi#le$ Re#onne#t the right ide %ind hield %a her ho e to the right %a her no55le lo#ated on the under ide of the #o%l #over$ 83$ Engage the retainer that e#ure the #o%l #over to the front fender edge$ 86$ In tall and tighten the %ing nut that e#ure the front of the #o%l #over to the %i&er 'odule$ 87$ Engage the ,uarter turn fa tener that e#ure the outer end of the #o%l #over to the %i&er 'odule$ 88$ In tall and tighten the "olt that hold the lo%er area of the #o%l #over to the %i&er 'odule$ 89$ Re#onne#t the negative "attery #a"le and verify that the %i&er 'otor and %i&er lin+age are in the 0AR= &o ition$ 8:$ In tall the %i&er ar' in #orre#t &o ition over the %i&er ar' &ivot$ 8;$ In tall the %i&er ar'4to4%i&er ar' &ivot retaining nut and tighten to 18 ft$ l" $ ?37 N'@$ 9<$ 0u h do%n the %i&er ar' #a& #over and engage the #li& that e#ure the out ide end of the #over to the %i&er ar'$

9/$ Re#onne#t the negative "attery #a"le$ 91$ O&erate the %ind hield %i&er and en ure they %or+ and &ar+ &ro&erly$ 93$ Refill the #ooling y te' %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater$ (leed the #ooling y te'$ 96$ Start the engine$ Che#+ for lea+ and &ro&er engine o&eration$

E*hau t Manifold
REMOVAL & INSTALLATION
1$6L Engine
/$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ 2i #onne#t the e*hau t &i&e fro' the e*hau t 'anifold at the fle* )oint$ A&&ly &enetrating oil on the e*hau t 'anifold4to4e*hau t &i&e flange "olt to aid in re'oval$ It 'ay "e ne#e ary to re'ove the entire e*hau t y te'$ 2eta#h the o*ygen en or %iring #onne#tor at the rear of the e*hau t 'anifold$ Re'ove the eight 'anifold atta#hing "olt and re'ove the 'anifold fro' the #ylinder head$

6$ 7$

Tighten the exhaust manifold bolts in the se%uence shown to prevent exhaust lea-s&'.() engine 9"emoval should be in reverse order: To install: 8$ Thoroughly #lean all &art $ 2i #ard the ga +et ?if e,ui&&ed@ and #lean all ga +et urfa#e of the 'anifold and #ylinder head$ Te t the 'anifold ga +et urfa#e for flatne %ith a traightedge and feeler gauge$ The urfa#e 'u t "e flat %ithin <$<<8 in#he &er foot ?<$/7'' &er 3<#'@ of 'anifold length$ In &e#t the 'anifold for #ra#+ or di tortion$ Re&la#e if ne#e ary$

9$ :$

In tall the 'anifold to the vehi#le %ith a ne% ga +et$ 2O NOT A00LD SEALER$ In tall the eight 'anifold "olt and tighten! tarting at the #enter and %or+ing out%ard in "oth dire#tion ! to /9 ft$ l" $ ?13 N'@$ ;$ Re#onne#t the o*ygen en or %iring #onne#tor$ /<$ Re#onne#t the e*hau t &i&e to the e*hau t 'anifold and tighten the fa tener to 1< ft$ l" $ ?1: N'@$ //$ Re#onne#t the negative "attery #a"le$ Start the engine and allo% it to idle %hile in &e#ting the 'anifold for e*hau t lea+ $

3$<L Engine

To remove an exhaust manifold, unbolt the heat shield ...

... and remove it to access the manifold fasteners

;se an extension if necessary to access the manifold fasteners

In addition to removing the exhaust pipe from the manifold, be sure to remove the crossover pipe&to&exhaust manifold fasteners /$ 1$ 3$ 6$ 7$ 8$ 9$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ 2i #onne#t the e*hau t &i&e fro' the rear e*hau t 'anifold! at the fle* )oint$ Re'ove the rear e*hau t 'anifold heat hield$ Re'ove the rear e*hau t 'anifold4to4#ylinder head nut and re'ove the e*hau t 'anifold$ Re'ove the #ro over &i&e4to4e*hau t 'anifold atta#hing "olt $ Lo%er the vehi#le and re'ove the heat hield fro' the front e*hau t 'anifold$ Re'ove the "olt fa tening the #ro over &i&e to the front e*hau t 'anifold$ Re'ove the front e*hau t 'anifold4to4#ylinder head nut and re'ove the e*hau t 'anifold$ Clean the ga +et 'ounting urfa#e $ In &e#t the 'anifold for #ra#+ ! flatne and-or da'age$

:$

To install:

Install the gasket with the num ers &-'-( em ossed on the top on the rear ank and those with the num ers $-)-* on the front +radiator side, ank. ;$ Rai e and afely u&&ort the vehi#le$

/<$ In tall the ne% ga +et and rear e*hau t 'anifold to the #ylinder head$ In tall and tighten the rear e*hau t 'anifold4to4#ylinder head nut to /97 in#h l" $ ?1< N'@$

5ith everything unfastened, the manifold can be removed from the cylinder head

1lways use a new gas-et to prevent lea-age 9/ote how the exhaust manifold gas-et doubles as a heat shield:

0efore installing the exhaust manifold, clean both the cylinder head ...

... and manifold mating surfaces, to ensure a clean surface for the new gas-ets to seal properly //$ Atta#h the e*hau t &i&e to the e*hau t 'anifold and tighten the houlder "olt to 1< ft$ l" $ ?1: N'@ /1$ Atta#h the #ro over &i&e to the e*hau t 'anifold and tighten the "olt to 7/ ft$ l" $ ?8; N'@$ /3$ In tall the rear e*hau t 'anifold heat hield and tighten the heat hield 'ounting fa tener to /3< in#h l" $ ?/7 N'@$ /6$ Conne#t the EGR tu"e to the rear 'anifold! if re'oved! and re#onne#t the o*ygen en or$ /7$ Lo%er the vehi#le$ /8$ In tall the front e*hau t 'anifold and atta#h the e*hau t #ro over &i&e$ Tighten the "olt to 7/ ft$ l" $ ?8; N'@$ /9$ In tall the front e*hau t 'anifold heat hield and tighten the "olt to /3< in#h l" $ ?/7 N'@$ /:$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for e*hau t lea+ $

3$3L and 3$:L Engine

"ear exhaust manifold mounting detail&*.* and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 9$ :$ ;$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt$ Re'ove the alternator$ Rai e and afely u&&ort the vehi#le$ 2i #onne#t the e*hau t &i&e fro' the rear e*hau t 'anifold at the fle* )oint$ Se&arate the EGR tu"e fro' the e*hau t 'anifold and di #onne#t the o*ygen en or$ Re'ove the alternator-&o%er teering u&&ort trut$ Re'ove the #ro over &i&e atta#hing "olt to the rear e*hau t 'anifold$ Re'ove the rear e*hau t 'anifold heat hield$

Front exhaust manifold mounting detail&*.* and *.,) engines

!rossover pipe mounting detail&*.* and *.,) engines /<$ Re'ove the rear 'anifold4to4#ylinder head nut ! then re'ove the rear 'anifold$ //$ Lo%er the vehi#le and re'ove the front e*hau t 'anifold heat hield$ /1$ Re'ove the front e*hau t 'anifold #ro over &i&e "olt $ /3$ Re'ove the front 'anifold4to4#ylinder head nut ! then re'ove the front e*hau t 'anifold$ /6$ Clean the 'ounting urfa#e $ In &e#t the 'anifold for #ra#+ or other da'age$ .ith a traightedge and feeler gauge! #he#+ for flatne $ Standard i <$<<6 in$ ?<$/''@ %ith <$<<: in$ ?<$1''@ out4of4flatne the ervi#e li'it$ If di torted "eyond the e &e#ifi#ation ! re&la#e the 'anifold$ To install: /7$ Rai e and afely u&&ort the vehi#le$ /8$ In tall the ne% ga +et and rear 'anifold$ Tighten the 'anifold4to4#ylinder head nut to /9 ft$ l" $ ?13 N'@$ /9$ In tall the rear e*hau t 'anifold heat hield$ Tighten the heat hield 'ounting fa tener to /9 ft$ l" $ ?13 N'@$ /:$ In tall the alternator unit$ /;$ Conne#t the e*hau t &i&e to the e*hau t 'anifold and tighten the "olt to 1< ft$ l" $ ?1: N'@$ 1<$ Conne#t the #ro over &i&e to the rear 'anifold and tighten the "olt to 17 ft$ l" $ ?33 N'@$ 1/$ Conne#t the o*ygen en or$ 11$ Conne#t the EGR tu"e to the e*hau t 'anifold and in tall the alternator-&o%er teering u&&ort trut$ 13$ Lo%er the vehi#le$ 16$ In tall the ne% ga +et and front e*hau t 'anifold to the #ylinder head$ Tighten the e*hau t 'anifold4to4#ylinder head nut to /9 ft$ l" $ ?13 N'@$ 17$ Conne#t the #ro over &i&e to the front 'anifold$ 18$ In tall the front 'anifold heat hield$ Tighten the heat hield 'ounting fa tener to 1<< in#h l" $ ?13 N'@$ 19$ In tall the a##e ory drive "elt$ 1:$ Re#onne#t the negative "attery #a"le$ 1;$ Start the engine and #he#+ for e*hau t lea+ $

Radiator
REMOVAL & INSTALLATION

0efore removing the hood latch, mar- it s location on the crossmember with a paint mar-er or other tool

7nce the hood latch is matchmar-ed, remove it from the crossmember 9without disconnecting the cable: and set it aside /$ 2i #onne#t the negative "attery #a"le$

CAUTION
2o not remove the radiator cap or drain with the cooling system hot and under pressure or serious personal injury can occur from hot pressuri<ed coolant. 1$ 0la#e a drain &an under the radiator drain$ O&en the radiator drain &lug and allo% the #oolant to drain$

3$ 6$ 7$ 8$ 9$ :$ ;$

Re'ove the air inta+e re onator fro' the air #leaner a e'"ly$ Re'ove the Coolant Re#overy Sy te' ?CRS@ overflo% tan+ filler ne#+ ho e$ 2i #onne#t the #ooling fan ele#tri#al #onne#tor lo#ated on the left ide of the #ooling fan 'odule$ Re'ove the CRS overflo% tan+ 'ounting #re% fro' the u&&er radiator #ro 'e'"er$ Re'ove the u&&er radiator4to4#ro 'e'"er 'ounting #re% $ If e,ui&&ed! di #onne#t the engine "lo#+ heater %iring #onne#tor$ Re'ove the u&&er radiator #ro 'e'"er$

"emove the grill extension ...

... and the upper radiator&to&crossmember bolts, then ...

... unbolt the crossmember ...

... and lift it from the front of the vehicle /<$ Re'ove the entire air #leaner a e'"ly$

//$ 2i #onne#t and &lug the auto'ati# tran a*le oil #ooler line fro' the radiator$ /1$ 2i #onne#t the u&&er and lo%er radiator ho e fro' the radiator$ Re'ove the lo%er radiator ho e #li& fro' the #ooling fan 'odule$ /3$ Re'ove the A-C #onden er 'ounting fa tener and e&arate the A-C #onden er fro' the radiator$ (e ure the #onden er i u&&orted in &o ition$ /6$ Re'ove the A-C filter-drier 'ounting "ra#+et! 1 'ounting "olt to the #ooling fan 'odule and 1 'ounting nut to the filter-drier$ Re'ove the 'ounting "ra#+et$ /7$ Carefully lift the radiator out of the engine #o'&art'ent$ (e #areful not to da'age the radiator #ooling fin or %ater tu"e during re'oval$ To install:

/8$ (e ure the air eal are &ro&erly &o itioned "efore in tallation of the radiator$ Lo%er the radiator into &o ition and eat the radiator %ith the ru""er i olator into the 'ounting hole &rovided$ /9$ In tall the A-C filter-drier and 'ounting "ra#+et onto the #ooling fan 'odule$ In tall the "ra#+et 'ounting fa tener $

=pring&type hose clamps can be removed with pliers

5orm&type hose clamps can be removed with a screwdriver, or in some cases, a small soc-et /:$ In tall the A-C #onden er to the radiator$ /;$ 1<$ 1/$ 11$ 13$ 16$ >n&lug and #onne#t the tran a*le oil #ooler line to the radiator$ Conne#t the u&&er and lo%er radiator ho e to the radiator$ Conne#t the CRS overflo% tan+ filler ne#+ ho e to the radiator$ Re#onne#t the #ooling fan 'otor ele#tri#al #onne#tor$ In tall the entire air #leaner a e'"ly$ In tall the u&&er radiator #ro 'e'"er$

17$ In tall the u&&er radiator 'ounting #re% and tor,ue to /<7 in#h l" $ ?/1 N'@$ 18$ Re#onne#t the engine "lo#+ heater ele#tri#al #onne#tor! if e,ui&&ed$ 19$ In tall the CRS overflo% tan+ 'ounting #re% to the u&&er radiator #ro 'e'"er$ Tor,ue the #re% to /: in#h l" $ ?1 N'@$

=pecial tools are available to ma-e removing hoses from connections easier

To avoid spilling residual coolant, it s a good idea to plug the radiator connections and hoses

;nbolt the lower radiator mounting brac-ets

7nce all of the components are removed or set aside, the radiator can be removed from the vehicle 1:$ In tall the air inta+e re onator$ 1;$ Refill the #ooling y te' %ith a 7<-7< 'i*ture of #lean! fre h ethylene gly#ol antifree5e and %ater to the &ro&er level$ 3<$ Re#onne#t the negative "attery #a"le$ 3/$ Start the engine and run until it rea#he nor'al o&erating te'&erature! then #he#+ the #oolant level and the auto'ati# tran 'i ion fluid level$ Add fluid ! if ne#e ary$

Ele#tri# Cooling Aan
REMOVAL & INSTALLATION

!ooling fan assembly mounting points Cli#+ to enlarge

;nplug the connectors that supply power to the cooling fan

"emoving the cooling fan assembly The electric cooling fan assem ly cannot e disassem led. If the fan is warped, cracked or otherwise damaged, it must e replaced as an assem ly. /$ 1$ 3$ 6$ 7$ 8$ 9$ :$ ;$ /<$ //$ /1$ /3$ /6$ /7$ /8$ /9$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ Re'ove the radiator outlet ho e fro' the radiator ho e retaining #li& and re'ove the retaining #li& fro' the hroud$ If e,ui&&ed! re'ove the lo%er au*iliary tran a*le #ooler line fro' the retaining #li& on the #ooling fan 'odule hroud$ Lo%er the vehi#le$ Re'ove the entire air #leaner a e'"ly and the air inta+e re onator$ 2i #onne#t the fan 'otor ele#tri#al #onne#tor? @$ Re'ove the Coolant Re#overy Sy te' ?CRS@ 'ounting #re% fro' the u&&er radiator #ro 'e'"er$ 2i #onne#t the 'ount to the u&&er radiator fro' the radiator #ro 'e'"er$ Re'ove the u&&er radiator #ro 'e'"er$ Re'ove the #ooling fan 'odule 'ounting #re% $ If e,ui&&ed! re'ove the u&&er au*iliary tran a*le #ooler line fro' the retaining #li& on the #ooling fan 'odule hroud$ 2i #onne#t and &lug the tran a*le oil #ooler line fro' the radiator fitting on the lo%er left ide$ Rai e and afely u&&ort the vehi#le$ Re'ove the filter-drier! #ooling fan 'odule and radiator 'ounting "olt lo#ated on the lo%er right of the #ooling fan 'odule$ Lo%er the vehi#le$ Re'ove the u&&er #ooling fan 'odule4to4radiator retaining #li& $ Re'ove the #ooling fan 'odule fro' the vehi#le$

To install: /:$ In tall the #ooling fan 'odule a e'"ly into the retaining #li& of the radiator$

/;$ In tall the u&&er #ooling fan 'odule4to4radiator retaining #li& $ 1<$ Rai e and afely u&&ort the vehi#le$

1/$ In tall the filter-drier! #ooling fan 'odule and radiator 'ounting "olt lo#ated on the lo%er right of the #ooling fan 'odule$ 11$ Lo%er the vehi#le$ Re#onne#t the tran a*le #ooler line to the radiator fitting on the lo%er left ide$ 13$ If e,ui&&ed! in tall the u&&er au*iliary tran a*le #ooler line to the retaining #li& on the #ooling fan 'odule hroud$ 16$ In tall the #ooling fan 'odule retaining #re% and tor,ue to /<7 in#h l" $ ?/1 N'@$ 17$ In tall the entire air #leaner a e'"ly$ 18$ In tall the u&&er radiator #ro 'e'"er and #onne#t the u&&er radiator 'ount to the #ro 'e'"er$ Tor,ue the 'ounting fa tener to /<7 in#h l" $ ?/1 N'@$ 19$ In tall the Coolant Re#overy Sy te' ?CRS@ 'ounting #re% to the u&&er radiator #ro 'e'"er$ Tor,ue the 'ounting #re% to /: in#h l" $ ?1 N'@$ 1:$ Re#onne#t the fan 'otor ele#tri#al #onne#tor$ 1;$ In tall the air inta+e re onator to the air #leaner a e'"ly$ 3<$ Rai e and afely u&&ort the vehi#le$ 3/$ If e,ui&&ed! in tall the lo%er au*iliary tran a*le #ooler line to the retaining #li& on the #ooling fan 'odule hroud$ 31$ In tall the radiator outlet ho e retainer #li& to the fan 'odule hroud$ 33$ In tall the radiator outlet ho e to the retaining #li&$ Lo%er the vehi#le$ 36$ Re#onne#t the negative "attery #a"le$ Run the engine and #he#+ for &ro&er #ooling fan o&eration %hen the engine rea#he o&erating te'&erature$

TESTING
5hen diagnosing an inoperative cooling fan it may be necessary to use a diagnostic scan tool to monitor engine coolant temperature and the engine control computer. /$ 1$ 3$ 6$ 7$ 8$ 0erfor' a vi ual in &e#tion of the #ooling fan$ If the fan doe not turn %ith ea e! the fan 'otor i ei5ed and need to "e re&la#ed$ Che#+ all the fu e and fu i"le lin+ related to the #ooling fan #ir#uit$ Che#+ the integrity of the ele#tri#al #onne#tion related to the #ooling fan #ir#uit$ Che#+ the #ooling fan 'otor$ Che#+ the relay a o#iated %ith the #ooling fan #ir#uit$ > ing a #an tool! deter'ine if the engine #ontrol #o'&uter i #alling for the fan to a#tivate$

Cooling Aan Motor
/$ 1$ 3$ 6$ 2i #onne#t the negative "attery #a"le$ 2i engage the #ooling fan 'otor #onne#tor$ Identify and la"el the ground and the &o%er ter'inal of the #ooling fan #onne#tor u ing the %iring diagra' &rovided$ > ing )u'&er lead %ith a fu e in erie ! a&&ly "attery voltage to the a&&ro&riate ter'inal of the #ooling fan$

CAUTION
>eep away from the fan blades when performing this procedure. 7$ The #ooling fan hould o&erate$ If not! re&la#e the #ooling fan$

If the cooling fan functions properly during this test, proceed to the cooling fan relay test.

Cooling Aan Relay
/$ 1$ 3$ Turn the ignition OAA$ Re'ove the relay$ Lo#ate the t%o ter'inal on the relay! %hi#h are #onne#ted to the #oil %inding $ Che#+ the relay #oil for #ontinuity$ Conne#t the #o''on 'eter lead to ter'inal :7 and &o itive 'eter lead to ter'inal :8$ There hould "e #ontinuity$ If not! re&la#e the relay$

;se an ohmmeter to chec- for circuit continuity of the coil in the relay 6$ Che#+ the o&eration of the internal relay #onta#t $ /$ Conne#t the 'eter lead to ter'inal 3< and :9$ Meter &olarity doe not 'atter for thi te&$ 1$ A&&ly &o itive "attery voltage to ter'inal :8 and ground to ter'inal :7$ The relay hould #li#+ a the #onta#t are dra%n to%ard the #oil and the 'eter hould indi#ate #ontinuity$ Re&la#e the relay if your re ult are different$

If the relay functions properly during this test, inspect the coolant temperature sensor and the cooling fan system wiring for defects.

.ater 0u'&
REMOVAL & INSTALLATION
1$6L Engine

5ater pump location on '.() engines Cli#+ to enlarge

5hen installing the pump, ma-e sure that the 7&ring is fully seated inside the groove Cli#+ to enlarge /$ 2i #onne#t the negative "attery #a"le$

This procedure re-uires removing the engine timing elt and the auto-tensioner. The factory specifies that the timing marks should always e aligned efore removing the timing elt. .et the piston in the /o. & cylinder to T"0 on the compression stroke. This should align all timing marks on the crankshaft sprocket and oth camshaft sprockets. 1$ 3$ 6$ Rai e and afely u&&ort the vehi#le$ Re'ove the right inner &la h hield$ Re'ove the a##e ory drive "elt $

7$ 8$ 9$

0la#e a drain &an under the radiator drain &lug$ 2rain the #ooling y te'$ Su&&ort the engine and re'ove the right 'otor 'ount$ Re'ove the &o%er teering &u'& 'ounting "ra#+et "olt and &la#e the &u'&-"ra#+et a e'"ly off to one ide$ 2o not di #onne#t the &o%er teering fluid line $ :$ Re'ove the right engine 'ount "ra#+et$ ;$ Re'ove the front ti'ing "elt u&&er and lo%er #over $ /<$ Loo en the ti'ing "elt ten ioner "olt and re'ove the "elt ten ioner and ti'ing "elt$

WARNING
5ith the timing belt removed, 27 /7T rotate the camshaft or cran-shaft or damage to the engine could occur. //$ Re'ove the #a' haft &ro#+et $ .ith the ti'ing "elt re'oved! re'ove "oth #a' haft &ro#+et "olt $ 2o not allo% the #a' haft to turn %hen the #a' haft &ro#+et are "eing re'oved$ /1$ Re'ove the rear ti'ing "elt #over to a##e the %ater &u'&$ /3$ Re'ove the %ater &u'& atta#hing "olt $ /6$ Re'ove the %ater &u'&$ To install: /7$ Thoroughly #lean all &art $ Re&la#e the %ater &u'& if there are any #ra#+ ! ign of #oolant lea+age fro' the haft eal! loo e or rough turning "earing! da'aged i'&eller or &ro#+et! or the &ro#+et flange i loo e or da'aged$ /8$ Clean all ealing urfa#e $ In tall a ne% ru""er O4ring into the %ater &u'& O4 ring groove$ Be sure the O-ring is properly seated in the water pump groove efore tightening the olts. #n improperly located O-ring may cause damage to the O-ring and cause a coolant leak. /9$ In tall the %ater &u'& to the engine and tighten the "olt to /<7 in#h l" $ ?/1 N'@$ /:$ 0re uri5e the #ooling y te' to /7 & i ?/<3 +0a@ and #he#+ for lea+ $ If o+ay! relea e the &re ure and #ontinue the a e'"ly &ro#e $ /;$ In tall the rear ti'ing "elt #over$ 1<$ In tall the #a' haft &ro#+et and tighten the atta#hing "olt to 97 ft$ l" $ ?/</ N'@$ To 'aintain ti'ing 'ar+ align'ent! 2O NOT allo% the #a' haft to turn %hile the &ro#+et "olt are "eing tightened$

WARNING
2o not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner 3;=T be compressed in a vise. 1/$ In tall the ti'ing "elt ten ioner and ti'ing "elt$ (e ure to &ro&erly ten ion the ti'ing "elt$ 11$ In tall the front u&&er and lo%er ti'ing "elt #over $ 13$ In tall the right engine 'ount "ra#+et and engine 'ount$ 16$ In tall the #ran+ haft da'&er and tighten the #enter "olt to /<7 ft$ l" $ ?/61 N'@$ 17$ In tall the right inner &la h hield$ 18$ Lo%er the vehi#le$

19$ In tall the &o%er teering &u'& "ra#+et and &o%er teering &u'&$ Tighten the "ra#+et 'ounting "olt to 6< ft$ l" $ ?76 N'@$ 1:$ In tall and ad)u t the drive "elt $ 1;$ Refill the #ooling y te' u ing a 7<-7< 'i*ture of %ater and ethylene gly#ol antifree5e$ (leed the #ooling y te'$ 3<$ Start the engine and #he#+ for &ro&er o&eration$ 3/$ Che#+ and to& off the #ooling y te'! if ne#e ary$

3$<L Engine

5ater pump mounting detail&*.+) engine Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ 2rain the #ooling y te'$ Re'ove the drive "elt $ Re'ove the ti'ing "elt #over and the ti'ing "elt$ Re'ove the %ater &u'& 'ounting "olt $ Se&arate the %ater &u'& fro' the %ater inlet &i&e and re'ove the %ater &u'&$ In &e#t the %ater &u'& and re&la#e a ne#e ary$

To install: 9$ :$ ;$ Clean all ga +et and O4ring urfa#e on the %ater &u'& and %ater &i&e inlet tu"e$ .et a ne% O4ring %ith %ater and in tall it on the %ater inlet &i&e$ In tall a ne% ga +et on the %ater &u'&$

/<$ In tall the &u'& inlet o&ening over the %ater &i&e and &re until the &i&e i #o'&letely in erted into the &u'& hou ing$ //$ In tall the %ater &u'&4to4"lo#+ 'ounting "olt and tighten to 1< ft$ l" $ ?19 N'@$ /1$ In tall the ti'ing "elt and ti'ing "elt #over $ In tall and ad)u t the drive "elt $ /3$ Re#onne#t the negative "attery #a"le$ Aill the #ooling y te' to the &ro&er level %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater$ /6$ Run the engine and #he#+ for lea+ $ To& off the #oolant level! if ne#e ary$

3$3L and 3$:L Engine

5ater pump location&*.* and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 9$ 2i #onne#t the negative "attery #a"le$ 2rain the #ooling y te'$ Re'ove the er&entine "elt$ Rai e and afely u&&ort the vehi#le$ Re'ove the right front %heel and lo%er fender hield$ Re'ove the %ater &u'& &ulley$ Re'ove the five 'ounting "olt and re'ove the &u'& fro' the engine$ 2i #ard the O4ring$ Clean the O4ring ealing urfa#e and in &e#t the %ater &u'& for da'age! #ra#+ ! eal lea+ ! and loo e or rough turning "earing $

5hen installing the pump, ma-e sure that the 7&ring is properly seated in the groove in the pump body Cli#+ to enlarge To install: :$ ;$ /<$ //$ /1$ /3$ /6$ In tall a ne% O4ring into the %ater &u'& groove$ In tall the &u'& onto the engine$ Tighten the 'ounting "olt to /<: in#h l" $ ?/1 N'@$ In tall the %ater &u'& &ulley$ Tighten the %ater &u'& &ulley "olt to 1< ft$ l" $ ?1: N'@$ In tall the fender hield and %heel$ Tighten the %heel lug nut ! in e,uen#e! to ;7 ft$ l" $ ?/1; N'@$ Lo%er the vehi#le$ In tall the er&entine "elt$ Refill the #ooling y te' to the #orre#t level %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater$ (leed the #ooling y te'$ Re#onne#t the negative "attery #a"le! run the vehi#le until the ther'o tat o&en ! fill the overflo% tan+ and #he#+ for lea+ $ On#e the vehi#le ha #ooled! re#he#+ the #oolant level$

Cylinder Head
REMOVAL & INSTALLATION CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1$6L Engine

!ylinder head bolt tightening se%uence&'.() engine Cli#+ to enlarge /$ 1$ 3$ 6$ 0ro&erly relieve the fuel y te' &re ure$

2i #onne#t the negative "attery #a"le$ 0la#e a large drain &an under the radiator drain &lug$ O&en u& the drain &lug and drain the #ooling y te'$ Re'ove the air #leaner a e'"ly and di #onne#t all va#uu' line ! ele#tri#al %iring and fuel line fro' the throttle "ody$

7$ 8$ 9$ :$ ;$ /<$ //$ /1$ /3$ /6$ /7$

/8$

/9$ /:$ /;$ 1<$

1/$

2i #onne#t the throttle lin+age$ Re'ove the a##e ory drive "elt $ 2i #onne#t the &o%er "ra+e va#uu' ho e fro' the inta+e 'anifold$ Rai e and afely u&&ort the vehi#le$ 2i #onne#t the e*hau t &i&e fro' the e*hau t 'anifold$ Lo%er the vehi#le a re,uired to re'ove the &o%er teering &u'&$ 2o not di #onne#t the fluid line $ Set the &u'& a ide$ La"el the &ar+ &lug %ire for #orre#t in tallation$ 2eta#h the #oil &a#+ %iring #onne#tor and re'ove the #oil &a#+ and &ar+ &lug %ire fro' the engine$ 2eta#h the #a' en or and fuel in)e#tor %iring #onne#tor $ Re'ove the ti'ing "elt #over ! ti'ing "elt and #a' haft &ro#+et $ Re'ove the ti'ing "elt idler &ulley and rear ti'ing "elt #over$ Re'ove the #ylinder head #over 'ounting fa tener and #ylinder head #over$ Re'ove the ground tra&$ Identify the #a' haft ! if they are to "e reu ed! for later in tallation$ The #a' haft are not inter#hangea"le$ Re'ove the #a' haft "earing #a& and the #a' haft $ Re'ove the #a' haft follo%er $ Any #o'&onent that are to "e reu ed 'u t "e in talled in their original lo#ation $ > e #are to identify and 'ar+ the &o ition of any re'oved valvetrain #o'&onent o they 'ay "e rein talled #orre#tly$ Re'ove the inta+e and e*hau t 'anifold $ Re'ove the #ylinder head "olt $ Re'ove the #ylinder head fro' the vehi#le! u ing #are not to da'age the alu'inu' ga +et urfa#e $ Re'ove all ga +et 'aterial fro' the ealing urfa#e of the #ylinder head and engine "lo#+$ (e #areful not to gouge or #rat#h the urfa#e of the alu'inu' head$ The #ylinder head hould "e #he#+ed for %ar&age u ing a good traightedge and feeler gauge $ 0la#e the traightedge on the "otto' of the #ylinder head fro' front to "a#+! then try to in ert the feeler gauge "et%een the head and the traightedge in everal &la#e $ If a feeler gauge larger than <$<<6 in$ ?<$/''@ fit "et%een the head and traightedge! ta+e the #ylinder head to a 'a#hine ho& for ervi#e "efore in talling it$ In &e#t the #a' haft "earing oil feed hole in the #ylinder head for #logging$ In &e#t the #a' haft "earing )ournal for %ear or #oring$ Che#+ the #a' urfa#e for a"nor'al %ear and da'age$ A vi i"le %orn groove in the roller &ath or on the #a' lo"e i #au e for re&la#e'ent$ Valve ervi#e 'ay "e &erfor'ed at thi ti'e$

To install: 11$ Clean all &art %ell$ Note that the #ylinder head "olt are tightened u ing a ne% &ro#edure$ The #ylinder head "olt hould "e #he#+ed #arefully (EAORE reu e$ If the thread are ne#+ed do%n the "olt hould "e re&la#ed %ith ne% "olt $ Ne#+ing #an "e #he#+ed "y holding a teel #ale or traightedge again t the thread $ If all the thread do not #onta#t the #ale! the "olt hould "e re&la#ed$ Ne% #ylinder head "olt are re#o''ended for any engine re"uild! e &e#ially if +no%n that the engine ha "een di a e'"led "efore$ 13$ (e ure "oth the to& of the engine "lo#+ and the "otto' of the #ylinder head are #lean$ In tall a ne% ga +et 'a+ing ure all hole align %ith the o&ening in the engine "lo#+$ Carefully et the #ylinder head in &la#e$ 16$ A&&ly #lean engine oil to the thread and under the head of the "olt $ In tall the "olt and tighten the' in e,uen#e u ing the follo%ing four u" te& B /$ Tighten all "olt to 17 ft$ l" $ ?36 N'@$ 1$ Tighten all "olt to 7< ft$ l" $ ?8: N'@$ 3$ Tighten all "olt again to 7< ft$ l" $ ?8: N'@$ "o not use a tor-ue wrench for the fourth step.

6$

Tighten all "olt an additional /-6 turn$

17$ The #a' haft end4&lay hould "e #he#+ed u ing the follo%ing &ro#edureB /$ Oil the #a' haft )ournal and in tall the #a' haft .ITHO>T the #a' follo%er a e'"lie $ In tall the rear #a' #a& and tighten the' to 17< in#h l" $ ?1: N'@$ 1$ Carefully &u h the #a' haft a far rear%ard a it %ill go$ 3$ Set u& a dial indi#ator to "ear again t the front of the #a' haft ?the &ro#+et end@$ Fero the indi#ator$ 6$ Move the #a' haft for%ard a far a it %ill go$ Read the dial indi#ator$ End4&lay &e#ifi#ation i <$<<14<$</< in$ ?<$<74<$/7''@$ 18$ .hen ati fied %ith the fit and #ondition of the #a' haft ! re'ove the #a' haft for in tallation of the #a' follo%er $ 19$ Lu"ri#ate the #a' haft follo%er %ith #lean engine oil$ In tall the #a' follo%er in their original &o ition on the hydrauli# ad)u ter and valve te'$

WARNING
0e sure none of the pistons are at Top 2ead !enter 9T2!: when installing the camshafts. 1:$ Lu"ri#ate the #a' haft "earing )ournal and #a' follo%er %ith #lean engine oil and in tall the #a' haft $ In tall right and left #a' haft "earing #a& No$ 1 through No$ 7 and right ide No$ 8$ Tighten the M8 fa tener to /<7 in#h l" $ ?/1 N'@ in e,uen#e$ 1;$ A&&ly Mo&arC Ga +et Ma+er or e,uivalent ealer to the No$ / and No$ 8 "earing #a& $ In tall the "earing #a& and tighten the M: fa tener to 17< in#h l" $ ?1: N'@$ The end #a& 'u t "e in talled "efore the eal 'ay "e in talled$ 3<$ A&&ly a light #oating of #lean engine oil to the li& of the ne% #a' haft eal$ In tall the #a' haft eal until it fit flu h %ith the #ylinder head$ 1efer to the timing elt 2nit 1epair .ection +21., for information on the timing elts and sprockets. 3/$ In tall the #a' haft &ro#+et ! if re'oved$ In tall the rear ti'ing "elt #over and ti'ing "elt u ing #are to "e ure all ti'ing 'ar+ are &ro&erly aligned$ In tall the ti'ing "elt #over$

WARNING
$erify that all timing mar-s are correct. If the timing belt or sproc-ets are incorrectly installed, engine damage will occur. Ta-e time to be sure all timing mar-s are correctly aligned. 31$ In tall the inta+e and e*hau t 'anifold $ 33$ Clean the #ylinder head #over and #ylinder head ga +et rail ?'ating urfa#e @$ Ma+e #ertain the rail are flat$ 36$ In tall ne% #ylinder head #over ga +et $ > e #areE 2O NOT allo% oil or olvent to #onta#t the ti'ing "elt a they #an deteriorate the ru""er and #au e tooth +i&&ing$ A&&ly Mo&arC Sili#one Ru""er Adhe ive Sealant! or e,uivalent! at the #a' haft #a& #orner and at the to& edge of the /-1 round eal$ 37$ In tall the #ylinder head #over a e'"ly to the head and tighten the fa tener in e,uen#e u ing the follo%ing three u" te& B

38$ 39$ 3:$ 3;$ 6<$ 6/$ 61$ 63$ 66$

Tighten all #ylinder head #over fa tener to 6< in#h l" $ ?6$7 N'@$ 1$ Tighten all fa tener to :< in#h l" $ ?; N'@$ 3$ Tighten all fa tener to /<7 in#h l" $ ?/1 N'@$ In tall the ground tra&$ In tall the ignition #oil &a#+ and re#onne#t the &ar+ &lug %iring$ Conne#t the #a' en or and fuel in)e#tor G %iring$ In tall the &o%er teering &u'& a e'"ly$ Conne#t the e*hau t &i&e to the e*hau t 'anifold$ Conne#t all va#uu' line and re'aining %iring$ Conne#t the throttle lin+age and fuel line $ In tall and ad)u t the a##e ory drive "elt $ Refill the #ooling y te'$ An oil and filter #hange i re#o''ended in#e #oolant #an enter the oil y te' %hen a head i re'oved$ Conne#t the re'aining air du#ting$ Conne#t the negative "attery #a"le and te t run the vehi#le$ Che#+ for lea+ and for &ro&er o&eration$

/$

3$<L Engine

1 brea-er bar should be used to loosen the cylinder head bolts /$ 1$ 3$ 0ro&erly relieve the fuel y te' &re ure$

6$ 7$

2i #onne#t the negative "attery #a"le$ 2rain the #ooling y te'$ Re'ove the a##e ory drive "elt and the air #onditioning #o'&re or fro' it 'ount and u&&ort it a ide$ Re'ove the alternator and &o%er teering &u'& fro' the "ra#+et and 'ove the' a ide$ Rai e the vehi#le and u&&ort afely$ Re'ove the right front %heel and the right inner &la h hield$ Re'ove the #ran+ haft &ulley and the tor ional da'&er$

1fter the cylinder head bolts are removed in the proper se%uence, lift the cylinder heads from the engine bloc-

!lean the cylinder head mating surfaces before installation 8$ Lo%er the vehi#le$ > ing a floor )a#+ and a "lo#+ of %ood &o itioned under the oil &an! rai e the engine lightly$ Re'ove the engine 'ount "ra#+et fro' the ti'ing #over end of the engine$

9$ :$

Re'ove the ti'ing "elt #over $ Re'ove the ti'ing "elt a de #ri"ed in the unit re&air e#tion in the "eginning of thi 'anual$ ;$ Hold the #a' haft &ro#+et u ing a uita"le tool and re'ove the #a' haft &ro#+et retaining "olt$ Re'ove the &ro#+et and the inner ti'ing "elt #over ?left "an+@ and-or alternator "ra#+et ?right "an+@$ /<$ La"el and di #onne#t the &ar+ &lug %ire fro' the &ar+ &lug $ //$ If re'oving the left ?front@ #ylinder head! re'ove the di tri"utor #a& and &ar+ &lug %ire $ Mar+ the &o ition of the rotor and di tri"utor in relation to the

/1$ /3$

/6$ /7$ /8$ /9$

#ylinder head and re'ove the di tri"utor$ Re'ove the di tri"utor drive ada&ter$ Re'ove the valve #over$ In tall the auto la h ad)u ter retainer on the ro#+er ar' $ Re'ove the #a' haft "earing #a&4to4#ylinder head "olt ?do not re'ove the "olt fro' the a e'"ly@$ Re'ove the ro#+er ar' ! ro#+er haft and "earing #a& a an a e'"ly$ Re'ove the #a' haft fro' the #ylinder head$ Re'ove the inta+e 'anifold a e'"ly$ Re'ove the e*hau t 'anifold and #ro over &i&e$ Re'ove the #ylinder head "olt tarting fro' the out ide and %or+ing in%ard$ Re'ove the #ylinder head fro' the engine$ Clean the ga +et 'ounting urfa#e and #he#+ the head ga +et urfa#e for lea+ ! da'age or %ar&ageE the 'a*i'u' %ar&age allo%ed i <$<<: in$ ?<$1<''@$

To install: /:$ Clean all &art %ell$ In tall the ne% #ylinder head ga +et over the do%el on the engine "lo#+$ /;$ In tall the #ylinder head on the engine "lo#+ and tighten the /<'' AllenC #ylinder head "olt in e,uen#e! u ing three even te& ! to :< ft$ l" $ ?/<: N'@$ 1<$ In tall the inta+e and e*hau t 'anifold $ 1/$ Lu"ri#ate the #a' haft %ith #lean engine oil and in tall on the #ylinder head$ 11$ A&&ly ili#one ealant to the #ylinder head at the front and rear #a' "earing #a& #onta#t area $ In tall the ro#+er ar' haft a e'"ly and tighten the "earing #a& "olt to :7 in#h l" $ ?/< N'@ in the follo%ing e,uen#eB No$ 3! No$ 1! No$ / and No$ 6$ Retighten to /:< in#h l" $ ?1< N'@ in the a'e e,uen#e$ 13$ If re'oved! in tall the di tri"utor drive ada&ter$ In tall a ne% #a' haft eal$ 16$ In tall the valve #over$ 17$ In tall the inner ti'ing "elt #over ?left "an+@ and-or alternator "ra#+et ?right "an+@$ 18$ 0o ition the #a' haft &ro#+et$ Hold the &ro#+et u ing a uita"le tool and in tall the #a' haft &ro#+et "olt$ Tighten the "olt to 9< ft$ l" $ ?;7 N'@$

2istributor drive extension&*.+) engine Cli#+ to enlarge

!ylinder head and roc-er arm shaft assemblies Cli#+ to enlarge

!ylinder head bolt removal se%uence Cli#+ to enlarge Be sure the timing elt sprocket timing marks are aligned.

19$ If re'oved! in tall the di tri"utor! aligning the 'ar+ 'ade during re'oval$ In tall the di tri"utor #a& and &ar+ &lug %ire $ 1:$ In tall the ti'ing "elt$ 1;$ In tall the ti'ing "elt #over and the engine u&&ort "ra#+et$ 3<$ In tall the tor ional da'&er and tighten the "olt to //1 ft$ l" $ ?/7/ N'@$ In tall the #ran+ haft &ulley $

3/$ In tall the inner &la h hield and the right front %heel$ Tighten the %heel lug nut to ;7 ft$ l" $ ?/1; N'@$ Lo%er the vehi#le$

!ylinder head bolt tightening se%uence Cli#+ to enlarge

Install the camshaft oil seal with the special tool Cli#+ to enlarge

;se the special tool to install a new camshaft end seal 9plug:

31$ In tall the alternator! &o%er teering &u'& and air #onditioning #o'&re

or$

33$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 36$ Refill the #ooling y te'$ Sin#e #oolant #an #onta'inate the engine oil %hen a #ylinder head i re'oved! an oil and filter #hange i re#o''ended$ 37$ Re#onne#t the negative "attery #a"le$ 38$ Start the engine and #he#+ for lea+ $ Che#+ the ignition ti'ing$

3$3L and 3$:L Engine

!ylinder head assembly&*.*) and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 9$ :$ 0ro&erly relieve the fuel y te' &re ure$

;$

2i #onne#t the negative "attery #a"le and drain the #ooling y te'$ Re'ove the inta+e 'anifold %ith the throttle "ody$ 2i #onne#t the #oil %ire ! ending unit %ire! heater ho e and "y&a ho e$ Re'ove the #lo ed ventilation y te'! eva&oration #ontrol y te' and #ylinder head #over? @$ Re'ove the e*hau t 'anifold? @$ Re'ove the ro#+er ar' and haft a e'"lie $ Re'ove the &u hrod and identify the' to en ure in tallation in their original &o ition $ Loo en the #ylinder head "olt in the rever e order of the tor,ue e,uen#e$ Re'ove the #ylinder head "olt and re'ove the #ylinder head? @ fro' the "lo#+$ Clean all ga +et 'ating urfa#e $

!ylinder head gas-et installation&*.*) and *.,) engines Cli#+ to enlarge

!hec-ing the cylinder head mounting bolts for stretching 9nec-ing:&*.*) and *.,) engines Cli#+ to enlarge

!ylinder head tightening se%uence&*.*) and *.,) engines

Cli#+ to enlarge To install: /<$ Clean the ga +et 'ounting urfa#e and in tall a ne% head ga +et to the "lo#+$ The cylinder head olts are tightened using the tor-ue yield method. The olts should e e3amined efore they are reused. If the threads are stretched, the olts should e replaced. .tretching can e checked y holding a straightedge against the threads. If all the threads do not contact the straightedge, the olt should e replaced. //$ In tall the #ylinder head to the "lo#+ %ith the "olt $ /1$ Tighten #ylinder head "olt No $ / through : in e,uen#e a follo% B /$ Tighten ea#h "olt to 67 ft$ l" $ ?8/ N'@$ 1$ Re&eat the e,uen#e and tighten the "olt to 87 ft$ l" $ ?:: N'@$ 3$ Re&eat the e,uen#e again! 'a+ing ure the "olt are at 87 ft$ l" $ ?:: N'@$ 6$ Ainally! turn ea#h "olt! in e,uen#e! /-6 turn$ 2o not u e a tor,ue %ren#h for thi te&$ 7$ Che#+ the tor,ue of ea#h "olt after the /-6 turn$ The tor,ue hould "e over ;< ft$ l" $ ?/11 N'@$ If not! re&la#e the "olt$ /3$ Tighten head "olt No$ ; to 17 ft$ l" $ ?33 N'@ after the other eight "olt have "een &ro&erly tightened$ /6$ In tall the &u hrod ! ro#+er ar' and haft ! and tighten the "olt to 17< in#h l" $ ?1: N'@$ /7$ 0la#e a dro& of ili#one ealer onto ea#h of the four 'anifold4to4#ylinder head ga +et #orner $

CAUTION
The inta-e manifold gas-et is composed of very thin and sharp metal. 8andle this gas-et with care or damage to the gas-et or personal injury could result. /8$ In tall the inta+e 'anifold ga +et and tighten the end retainer to /<7 in#h l" $ ?/1 N'@$ /9$ In tall the inta+e 'anifold and tighten the "olt in e,uen#e to /< in#h l" $ ?/ N'@$ Re&eat the e,uen#e! in#rea ing the tor,ue to 1<< in#h l" $ ?11 N'@$ Re#he#+ ea#h "olt! 'a+ing ure it i at 1<< in#h l" $ ?11 N'@ of tor,ue$ A the "olt are tightened! in &e#t the eal to en ure that they have not "e#o'e di lodged$ /:$ In tall the valve #over %ith a ne% ga +et$ Tighten the valve #over "olt to /<7 in#h l" $ ?/1 N'@$ In tall the e*hau t 'anifold and #ro over &i&e$ Tighten the "olt to 1< ft$ l" $ ?19 N'@ and the nut to /7 ft$ l" $ ?1< N'@$ /;$ In tall the #lo ed ventilation y te' and the eva&oration #ontrol y te'$ 1<$ Re#onne#t the #oil %ire ! ending unit %ire! heater ho e and "y&a ho e$ 1/$ En ure all %iring #onne#tion ! #a"le ! ho e ! va#uu' and fuel line have "een reatta#hed$ 11$ Refill the #ooling y te' to the #orre#t level$ Coolant #an #onta'inate the engine oil %hen &erfor'ing #ylinder head ervi#e$ An oil and filter #hange i re#o''ended$ 13$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $

Oil 0an

REMOVAL & INSTALLATION
1$6L Engine

7il pan sealant application&'.() engine /$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil$ Re'ove the oil &an atta#hing "olt $ Re'ove the oil &an$ Thoroughly #lean the in ide of the oil &an$ Clean the ga +et 'ating urfa#e of the oil &an and engine "lo#+$

To install: 9$ :$ ;$ /<$ //$ > ing a uita"le ga +et ealant! a&&ly a /-: in$ ?3''@ "ead at the oil &u'&4to4 engine "lo#+ &arting line$

In tall the ne% oil &an ga +et$ In tall the oil &an to the engine$ Tighten the oil &an atta#hing "olt to /<7 in#h l" $ ?/1 N'@$ In tall the oil &an drain &lug and ga +et$ Tighten the drain &lug to 17 ft$ l" $ ?36 N'@$ /1$ Lo%er the vehi#le$ /3$ Aill the engine %ith the #orre#t ty&e of #lean engine oil to the &ro&er level$ /6$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $

3$<L Engine

7il pan and related components&*.+) engines, except 4remier and 3onaco /$ 1$ 3$ 6$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil$ Re'ove the oil &an atta#hing "olt and re'ove the oil &an$

To install: 7$ 8$ 9$ Thoroughly #lean the in ide of the oil &an$ Clean the oil &an and engine "lo#+ ga +et 'ating urfa#e $ A&&ly RTV ealant to the oil &an$ In tall the oil &an! then tighten the "olt in e,uen#e to 7< in#h l" $ ?8 N'@$

3a-e certain that the silicone sealant is applied as shown in the illustration

7il pan bolt tightening se%uence :$ ;$ /<$ //$ /1$ In tall the oil &an drain &lug and tighten to 3< ft$ l" $ ?6< N'@$ Lo%er the vehi#le$ Refill the engine %ith the &ro&er ty&e and ,uantity of oil$ Conne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $ After the engine ha "een turned OAA! #he#+ the oil level and to& off! if ne#e ary$

3$3L and 3$:L Engine

7il pan sealing using 3opar? silicone rubber adhesive sealant&*.*) and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 2i #onne#t the negative "attery #a"le$ Re'ove the engine oil di& ti#+$ Rai e the vehi#le and u&&ort afely$ Re'ove the tor,ue #onverter "olt a##e #over! if e,ui&&ed$ 2rain the engine oil$ Re'ove the oil &an retaining "olt and re'ove the oil &an and ga +et$

To install:

3a-e certain that the new oil pan gas-et is correctly installed&*.*) and *.,) engines Cli#+ to enlarge 8$ 9$ :$ ;$ /<$ //$ /1$ /3$ Thoroughly #lean the in ide of the oil &an$ Thoroughly #lean and dry all ealing urfa#e ! "olt and "olt hole $ A&&ly a /-: in$ ?3''@ "ead of ili#one ealer to the #hain #over4to4"lo#+ 'ating ea' and the rear 'ain eal retainer4to4"lo#+ ea'$ In tall a ne% oil &an ga +et and in tall the oil &an to the engine$ In tall the retaining "olt and tighten to /<7 in#h l" $ ?/1 N'@$ In tall the oil &an drain &lug and tighten to 17 ft$ l" $ ?36 N'@$ In tall the tor,ue #onverter "olt a##e #over! if e,ui&&ed$ Lo%er the vehi#le$ In tall the oil di& ti#+$ Refill the engine %ith the &ro&er ty&e and ,uantity of oil$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $ After the engine ha "een turned OAA! #he#+ the oil level and to& off! if ne#e ary$

Oil 0u'&
REMOVAL & INSTALLATION
1$6L Engine

.xploded view of the oil pump&'.() engine Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 9$ :$ ;$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil and the engine #oolant into uita"le #ontainer $ Lo%er the vehi#le$ Re'ove the a##e ory drive "elt ! a re,uired$ Ta+e u& the %eight of the engine %ith an engine u&&ort tool and re'ove the right engine 'ount and "ra#+et$ (e ure the engine i afely u&&orted$ Re'ove the ti'ing "elt #over$ Loo en the ti'ing "elt ten ioner "olt and re'ove the ten ioner and the ti'ing "elt$ Rai e and afely u&&ort the vehi#le$

7il pump and pic-&up tube assembly&'.() engine Cli#+ to enlarge /<$ Re'ove the oil &an a e'"ly$ Re'ove the oil &u'& &i#+4u& tu"e and O4ring$

//$ > ing a uita"le &uller! re'ove the #ran+ haft da'&er fro' the front of the #ran+ haft$ /1$ > ing a uita"le &uller! dra% the #ran+ haft &ro#+et fro' the front of the #ran+ haft$ /3$ Loo en the oil &u'& "olt and re'ove$ Ta+e note of the lo#ation of ea#h "olt for rea e'"ly$ Re'ove the oil &u'& fro' the fa#e of the engine "lo#+$ If ne#e ary! ta& lightly %ith a oft fa#e 'allet$ > e #are %or+ing %ith light alloy &art $ /6$ To re'ove the relief valve fro' the &u'& "ody! un #re% threaded &lug! then &ull out the &ring and valve$ Note the order of the &art G re'oval$ To install: /7$ Clean all &art %ell for in &e#tion$ Re'ove the "olt holding the "a#+ #over to the &u'& "ody$ Re'ove the &u'& rotor $ The 'ating urfa#e of the oil &u'& hould "e 'ooth$ Re&la#e the &u'& #over if #rat#hed or grooved$ /8$ The &u'& hould "e #he#+ed for %ear "y #arefully 'ea uring the #o'&onent $ If oil pressure is low and the pump is within specifications, inspect for worn engine earings or other reasons for oil pressure loss. /9$ Clean all oil &u'& &art in uita"le olvent "efore a e'"ly$ A e'"le the &u'& %ith ne% &art a re,uired$ In tall the inner rotor %ith the #ha'fer fa#ing the #a t iron oil &u'& #over ?"a#+ of the &u'&@$ Tighten the #over "olt to /<7 in#h l" $ ?/1 N'@$ /:$ In tall the relief valve fir t! then the &ring! ga +et and #over #a& into the &u'& "ody$ Note that in talling the &ring fir t %ill eriou ly da'age the engine$ The relief valve goe in fir t$ Tighten the #over #a& to 6< ft$ l" $ ?77 N'@$ /;$ 0ri'e the oil &u'& "efore in tallation "y filling the rotor #avity %ith #lean engine oil$ 1<$ In ert a ne% oil ring eal in the oil &u'& #ounter"ore on the &u'& "ody di #harge &a age$ A&&ly Mo&arC Ga +et Ma+er or e,uivalent anaero"i# ty&e ga +et ealer! to the oil &u'& "ody flange$ Thi 'aterial #ure in the a" en#e of air %hen ,uee5ed "et%een t%o flat 'a#hined 'etal urfa#e $ Aor thi rea on! the 'ating urfa#e of "oth the &u'& "ody and the engine "lo#+ 'u t "e &otle ly #lean o all air %ill "e e*&elled %hen the &art are "olted together and tightened$ In tall the &u'& lo%ly onto the #ran+ haft aligning the oil &u'& rotor flat %ith the flat on the #ran+ haft until eated to the engine "lo#+$ Tighten the fa tener to 1< ft$ l" $ ?1: N'@$ 1/$ In tall a ne% front oil eal$ In tall the eal %ith the &ring ide to%ard the in ide of the engine$ Ta& the eal into &la#e until flu h %ith the #over$ 11$ In tall the #ran+ haft &ro#+et$ A &e#ial tool i u ed to dra% the &ro#+et onto the end of the #ran+ haft$ > e #are if u ing a u" titute tool$ 13$ Rai e and afely u&&ort the vehi#le$ 16$ In tall the oil &u'& &i#+4u& tu"e and O4ring$ Tighten the oil &u'& &i#+4u& tu"e 'ounting "olt to 1< ft$ l" $ ?1: N'@$ 17$ Thoroughly #lean the oil &an and "e ure the ga +et rail are in good #ondition$ > e Mo&arC Sili#one Ru""er Adhe ive Sealant or e,uivalent ealer at the oil &u'&4to4engine "lo#+ &arting line$ > e a ne% oil &an ga +et! in tall the oil &an and tighten the /3 oil &an "olt to /<7 in#h l" $ ?/1 N'@$ 18$ In tall a ne% oil filter$ 19$ Lo%er the vehi#le$ 1:$ In tall the ti'ing "elt and #over u ing the re#o''ended &ro#edure $ > e #are to "e ure all valve ti'ing 'ar+ are aligned$ Thi i 'o t i'&ortant$ Aailure to &ro&erly align the ti'ing 'ar+ %ill re ult in evere engine da'age$

1;$ In tall the #ran+ haft da'&er$ A &e#ial tool 'a+ing u e of a /1'' * /$97 * /7<'' "olt i u ed to dra% the #ran+ haft da'&er onto the end of the #ran+ haft$ > e #are if u ing u" titute tool $ Tighten the #enter "olt to /<7 ft$ l" $ ?/61 N'@$ 3<$ In tall the a##e ory drive "elt ! a re,uired$ Ad)u t the a##e ory drive "elt to the &ro&er ten ion$ 3/$ In tall the engine 'ount and "ra#+et! a re,uired$ Re'ove the engine u&&ort fi*ture fro' the vehi#le$ 31$ Refill the engine %ith the #orre#t ty&e and a'ount of fre h! #lean engine oil$ Refill the #ooling y te' %ith a 7<-7< 'i*ture of #lean! ethylene gly#ol antifree5e and %ater$ 33$ Te t run the vehi#le to #he#+ for lea+ $ An oil &re ure gauge hould "e in talled to verify &ro&er engine oil &re ure$

3$<L Engine

.xploded view of the oil pump assembly&*.+) engine Cli#+ to enlarge The oil pump assembly is mounted at the front of the cran-shaft. The oil pump housing also retains the front cran-shaft oil seal. =ince the timing belt must be removed to access the front cover, care must be ta-en. It is good practice to set the engine up to T2! /o. @ cylinder firing position. $erify that all timing mar-s on the cran-shaft and camshaft sproc-ets are properly aligned before removing the timing belt. This serves as a point of reference for all wor- that follows. $alve timing is most important and engine damage will result if the wor- is incorrect. /$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt $ Re'ove the air #onditioning #o'&re or fro' the 'ounting "ra#+et and lay it a ide! if e,ui&&ed$ Re'ove the #o'&re or 'ounting "ra#+et and ad)u ta"le drive "elt ten ioner fro' the engine$ Re'ove the &o%er teering &u'&-alternator "elt ten ioner 'ounting "olt and re'ove the ten ioner$ Re'ove the &o%er teering &u'& 'ounting "ra#+et "olt ! rear u&&ort lo#+nut and et the &o%er teering &u'& a ide$

6$ 7$

8$ 9$ :$ ;$ /<$ //$ /1$ /3$ /6$ /7$

Rai e and afely u&&ort the vehi#le$ 2rain the engine oil into a uita"le #ontainer$ Re'ove the right inner fender inner hield$ Re'ove the #ran+ haft drive &ulley "olt! drive &ulley and tor ional da'&er$ Lo%er the vehi#le$ 0la#e a floor )a#+ under the engine$ Se&arate the engine 'ount in ulator fro' the engine 'ount "ra#+et$ Rai e the engine lightly and re'ove the engine 'ount "ra#+et$ Re'ove the ti'ing "elt #over and ti'ing "elt$ Re'ove the #ran+ haft &ro#+et$ Re'ove the five oil &u'& 'ounting "olt ! then re'ove the oil &u'& a e'"ly$ Mar+ the 'ounting "olt for &ro&er in tallation during rea e'"ly$ Re'ove the front #ran+ haft oil eal fro' the oil &u'& #over$

To install: /8$ Clean all &art %ell for in &e#tion$ Re'ove the "olt holding the rear #over to the oil &u'& "ody$ Re'ove the &u'& rotor $ The 'ating urfa#e of the oil &u'& hould "e 'ooth$ Re&la#e the &u'& #over if #rat#hed or grooved$ /9$ The &u'& hould "e #he#+ed for %ear "y #arefully 'ea uring the #o'&onent $ If oil pressure is low and the pump is within specifications, inspect for worn engine earings or other reasons for oil pressure loss. /:$ Clean all oil &u'& &art in uita"le olvent "efore a &u'& %ith ne% &art a re,uired$ e'"ly$ A e'"le the

/;$ Clean the oil &u'& and engine "lo#+ ga +et urfa#e thoroughly$ 1<$ 0o ition a ne% ga +et on the &u'& a e'"ly and in tall on the #ylinder "lo#+$ (e ure the #orre#t length "olt are in their &ro&er lo#ation and tighten all "olt to // ft$ l" $ ?/7 N'@$ 1/$ In tall a ne% front #ran+ haft oil eal into the oil &u'& u ing eal in taller tool M24;;:9/9 or an e,uivalent eal driver tool$ 11$ In tall the #ran+ haft &ro#+et and ti'ing "elt$ Re#he#+ the engine ti'ing 'ar+ $ 13$ In tall the ti'ing "elt #over $ Tighten the ti'ing "elt #over fa tener to /< ft$ l" $ ?/6 N'@$ 16$ Rai e the engine lightly and in tall the engine 'ount "ra#+et$ In tall the engine 'ount in ulator into the engine 'ount "ra#+et$ 17$ In tall the tor ional da'&er! #ran+ haft drive &ulley and drive &ulley "olt$ Tighten to //1 ft$ l" $ ?/7/ N'@$ 18$ In tall the right fender inner &la h hield$ Lo%er the vehi#le$ 19$ In tall the &o%er teering 'ount "ra#+et and &o%er teering &u'&$ 1:$ In tall the &o%er teering-alternator "elt ten ioner$ 1;$ In tall the air #onditioning ad)u ta"le drive "elt ten ioner and 'ounting "ra#+et$ Tighten the 'ounting "olt to 6< ft$ l" $ ?76 N'@$ 3<$ In tall the air #onditioning #o'&re or$ Tighten the #o'&re or 'ounting "olt to 6< ft$ l" $ ?76 N'@$ 3/$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 31$ Re#onne#t the negative "attery #a"le$ 33$ Refill the #ran+#a e %ith the #orre#t a'ount of #lean engine oil and tart the engine$ Che#+ for lea+ $ 36$ Che#+ engine oil &re ure$

3$3L and 3$:L Engine

7il pump system operation Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ Re'ove the di& ti#+$ 2rain the #ooling y te'$ Rai e the vehi#le and u&&ort afely$ Su&&ort the engine and re'ove the right ide engine 'ount$ 2rain the oil and re'ove the oil &an$ Re'ove the oil &i#+4u& tu"e$ Re'ove the tran a*le in &e#tion #over! if ne#e ary$ Re'ove the ti'ing #hain #a e #over$ 2i a e'"le the oil &u'& a re,uired$

To install: 9$ Clean all &art %ell for in &e#tion$ Re'ove the "olt holding the "a#+ #over to the &u'& "ody$ Re'ove the &u'& rotor $ The 'ating urfa#e of the oil &u'& hould "e 'ooth$ Re&la#e the &u'& #over if #rat#hed or grooved$ The &u'& hould "e #he#+ed for %ear "y #arefully 'ea uring the #o'&onent $

:$

If oil pressure is low and the pump is within specifications, inspect for worn engine earings or other reasons for oil pressure loss. ;$ Clean all oil &u'& &art in uita"le olvent "efore a e'"ly$ A e'"le the &u'& %ith ne% &art a re,uired$ In tall the inner rotor %ith the #ha'fer fa#ing the #a t iron oil &u'& #over ?"a#+ of the &u'&@$ Tighten the #over "olt to /<7 in#h l" $ ?/1 N'@$

7il pump assembly and mounting bolt lengths Cli#+ to enlarge

7il pump assembly components Cli#+ to enlarge

!hec-ing the oil pump pressure after installation is complete Cli#+ to enlarge /<$ In tall the relief valve fir t! then the &ring! then the #over #a& into the &u'& "ody$ Note that in talling the &ring fir t %ill eriou ly da'age the engine$ The relief valve goe in fir t$ //$ 0ri'e the oil &u'& "y filling the rotor #avity %ith fre h oil and turning the rotor until oil #o'e out the &re ure &ort$ Re&eat a fe% ti'e until no air "u""le are &re ent$ /1$ In tall the #hain #a e #over$ Tighten the ti'ing #hain #a e #over "olt a follo% B /$ M: * /$1741< ft$ l" $ ?19 N'@ 1$ M/< * /$746< ft$ l" $ ?76 N'@

/3$ Clean out the oil &i#+4u& or re&la#e a re,uired$ Re&la#e the oil &i#+4u& O4ring and in tall the &i#+4u& to the &u'&$ Tighten the &i#+4u& tu"e retaining "olt to 17< in#h l" $ ?1: N'@$ /6$ In tall the oil &an$ In tall the right ide engine 'ount$ /7$ Lo%er the vehi#le$ In tall the di& ti#+$ Refill the engine %ith the &ro&er a'ount of oil$ /8$ Refill the #ooling y te' to the &ro&er level$ /9$ Re#onne#t the negative "attery #a"le and tart the engine$ /:$ Che#+ the area for lea+ and #he#+ the oil &re ure$

Cran+ haft 2a'&er
REMOVAL & INSTALLATION
/$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ Rai e and afely u&&ort the vehi#le$ Re'ove the right ide %heel and tire a e'"ly$ Re'ove the right inner &la h hield$ Re'ove the a##e ory drive "elt $ (rea+ the #ran+ haft da'&er "olt loo e! "ut do not re'ove it$ Re'ove the #ran+ haft da'&er$ If ne#e ary! atta#h a uita"le 34)a%ed &uller to the #ran+ haft da'&er! then tighten the #enter "olt and re'ove the da'&er "olt and da'&er$

"emove the right side inner fender splash shield

From below the vehicle, remove the accessory drive belts

"emove the cran-shaft damper center bolt and washer To install: 9$ In tall the #ran+ haft da'&er$ It 'ay "e ne#e ary to in tall the #ran+ haft da'&er u ing an M/14/$97 * /7<'' "olt! %a her! thru t "earing and nut fro' the #ran+ haft da'&er in tallation tool +it 89;1 or e,uivalent$ In tall the #ran+ haft da'&er "olt and tighten to the follo%ing &e#ifi#ation B o 1$6L engine4/<< ft$ l" $ ?/37 N'@$ o 3$<L engine4/<< ft$ l" $ ?/37 N'@ o 3$3L and 3$:L engine 46< ft$ l" $ ?76 N'@

:$

The pulley usually slides off of the cran-shaft

If a puller is used, sure to pull on the inner hub area only&*.*) and *.,) engines Cli#+ to enlarge

'.() engines may re%uire a special tool to press the pulley onto the cran-shaft Cli#+ to enlarge ;$ In tall the a##e ory drive "elt $

/<$ In tall the right inner &la h hield$ In tall the right ide %heel and tire a e'"ly$ //$ Carefully lo%er the vehi#le! then #onne#t the negative "attery #a"le$

Aront Cran+ haft Seal
REMOVAL AN2 INSTALLATION
1$6L Engine

To replace the front cran-shaft seal on '.() engines, the cran-shaft sproc-et must be removed with a puller Cli#+ to enlarge

The timing belt must be removed for this procedure. ;se care that all timing mar-s are aligned after installation or the engine will become damaged. /$ 1$ 3$ 6$ 7$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt $ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil$ Re'ove the #ran+ haft da'&er-&ulley u ing a )a% &uller tool$ Re'ove the ti'ing "elt #over and ti'ing "elt$

7nce the cran-shaft sproc-et is removed, a seal puller can be used to remove the seal from the rear timing belt cover Cli#+ to enlarge 8$ Re'ove the #ran+ haft ti'ing "elt &ro#+et u ing tool No$ 89;3 or e,uivalent$

WARNING
2o not nic- the seal surface of the cran-shaft or the seal bore. 9$ Re'ove the front #ran+ haft eal u ing tool No$ 899/ or e,uivalent eal &uller$ (e #areful not to da'age the eal #onta#t area of the #ran+ haft$

To install:

Installing the new seal with the special tool Cli#+ to enlarge

7nce the new seal is installed, the cran-shaft pulley is pressed onto the cran-shaft with a special

tool Cli#+ to enlarge :$ A&&ly a light #oating of #lean engine oil to the li& of the ne% oil eal$ In tall the ne% front #ran+ haft oil eal u ing oil eal in taller tool No$ 89:<4/ or e,uivalent$ In tall the ne% oil eal into the o&ening %ith the eal &ring fa#ing the in ide of the engine$ (e ure the oil eal i in talled flu h %ith the front #over$ In tall the #ran+ haft ti'ing "elt &ro#+et u ing tool No$ 89;1$ elt sprocket is facing you.

;$

Be sure the word 4F1O/T4 on the timing /<$ In tall the ti'ing "elt and ti'ing "elt #over$

//$ In tall the #ran+ haft da'&er-&ulley onto the #ran+ haft$ > e thru t "earing-%a her and /1M4/$97 * /7<'' "olt fro' &e#ial tool No$ 89;1$ In tall the #ran+ haft da'&er-&ulley retaining "olt and tor,ue to /<7 ft$ l" $ ?/61 N'@$ /1$ Lo%er the vehi#le$ /3$ In tall the a##e ory drive "elt $ Ad)u t the "elt to the &ro&er ten ion$ /6$ Refill the engine %ith the #orre#t a'ount of #lean engine oil$ /7$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $

3$<L Engine
/$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt $ Re'ove the air #onditioning #o'&re or fro' the 'ounting "ra#+et and lay it a ide! if e,ui&&ed$ Re'ove the #o'&re or 'ounting "ra#+et and ad)u ta"le drive "elt ten ioner fro' the engine$ Re'ove the &o%er teering &u'&-alternator "elt ten ioner 'ounting "olt and re'ove the ten ioner$ Re'ove the &o%er teering &u'& 'ounting "ra#+et "olt ! rear u&&ort lo#+ nut and et the &o%er teering &u'& a ide$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil into a uita"le #ontainer$ Re'ove the right inner fender inner &la h hield$ Re'ove the #ran+ haft drive &ulley "olt! drive &ulley and tor ional da'&er$ Lo%er the vehi#le$ 0la#e a floor )a#+ under the engine$ Se&arate the engine 'ount in ulator fro' the engine 'ount "ra#+et$ Rai e the engine lightly and re'ove the engine 'ount "ra#+et$ Re'ove the ti'ing "elt #over and ti'ing "elt$ Re'ove the #ran+ haft &ro#+et$ Re'ove the oil &u'& 'ounting "olt ?7@! and re'ove the oil &u'& a e'"ly$ Mar+ the 'ounting "olt for &ro&er in tallation during rea e'"ly$ Re'ove the front #ran+ haft oil eal fro' the oil &u'& #over u ing a uita"le eal re'oval tool$

6$ 7$ 8$ 9$ :$ ;$ /<$ //$ /1$ /3$ /6$ /7$

To install: /8$ Clean the oil &u'& and engine "lo#+ ga +et urfa#e thoroughly$ /9$ 0o ition a ne% ga +et on the &u'& a e'"ly and in tall on the #ylinder "lo#+$ Ma+e ure the #orre#t length "olt are in their &ro&er lo#ation and tor,ue all "olt to // ft$ l" $ ?/7 N'@$ /:$ In tall a ne% front #ran+ haft oil eal into the oil &u'& u ing eal in taller tool M24;;:9/9 or e,uivalent eal driver tool$

/;$ In tall the #ran+ haft &ro#+et and ti'ing "elt$ Re#he#+ engine ti'ing 'ar+ $ 1<$ In tall the ti'ing "elt #over $ Tor,ue the ti'ing "elt #over fa tener to /< ft$ l" $ ?/6 N'@$ 1/$ Rai e the engine lightly and in tall the engine 'ount "ra#+et$ In tall the engine 'ount in ulator into the engine 'ount "ra#+et$ 11$ In tall the tor ional da'&er! #ran+ haft drive &ulley and drive &ulley "olt$ Tor,ue to //1 ft$ l" $ ?/7/ N'@$ 13$ In tall the right fender inner &la h hield$ Lo%er the vehi#le$ 16$ In tall the &o%er teering 'ount "ra#+et and &o%er teering &u'&$ 17$ In tall the &o%er teering-alternator "elt ten ioner$ 18$ In tall the air #onditioning ad)u ta"le drive "elt ten ioner and 'ounting "ra#+et$ Tor,ue the 'ounting "olt to 6< ft$ l" $ ?76 N'@$ 19$ In tall the air #onditioning #o'&re or$ Tor,ue the #o'&re or 'ounting "olt to 6< ft$ l" $ ?76 N'@$ 1:$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 1;$ Re#onne#t the negative "attery #a"le$ 3<$ Refill the #ran+#a e %ith the #orre#t a'ount of #lean engine oil and tart the engine$ Che#+ for lea+ $

3$3L and 3$:L Engine

Install the new oil seal into the chain cover with the installation tool as shown Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ 2i #onne#t the negative "attery #a"le$ Rai e the vehi#le and u&&ort afely$ Re'ove the right front %heel and the &la h hield$ Re'ove the a##e ory drive "elt$ Re'ove the #ran+ haft &ulley "olt and re'ove the &ulley u ing a uita"le &uller$ Re'ove the #ran+ haft oil eal fro' the #over u ing #ran+ haft eal re'oval tool C46;;/ or e,uivalent$ (e #areful not to da'age the #ran+ haft eal urfa#e of the front ti'ing #hain #over$

To install: 9$ :$ Lu"ri#ate the li& of the ne% #ran+ haft oil eal %ith #lean engine oil$ > e tool C46;;1 or e,uivalent eal driver! to in tall the ne% #ran+ haft oil eal$

;$

/<$ //$ /1$ /3$ /6$

In tall the #ran+ haft &ulley u ing a "olt a&&ro*i'ately 7$; in$ long and thru t "earing and %a her &late$ Ma+e ure the &ulley "otto' out on the #ran+ haft eal dia'eter$ In tall the "olt and tor,ue to 6< ft$ l" $ ?76 N'@$ In tall the a##e ory drive "elt$ In tall the inner &la h hield and the %heel$ Tor,ue the %heel lug nut ! in a tar &attern! to ;7 ft$ l" $ ?/1; N'@$ Lo%er the vehi#le$ Re#onne#t the negative "attery #a"le$ Che#+ the engine oil levelE add oil a ne#e ary$ Start the engine and #he#+ for lea+ $

Ti'ing (elt Cover
REMOVAL & INSTALLATION
1$6L Engine

Front timing belt cover mounting locations&'.() engine Cli#+ to enlarge /$ 2i #onne#t the negative "attery #a"le$

1$ 3$ 6$ 7$ 8$ 9$ :$

Re'ove the right inner &la h hield$ Re'ove the a##e ory drive "elt $ Re'ove the #ran+ haft da'&er$ Re'ove the right engine 'ount$ 0la#e a floor )a#+ under the engine to u&&ort it %hile the engine 'ount i re'oved$ Re'ove the engine 'ount "ra#+et$ Re'ove the ti'ing "elt #over$

To install:

"ear timing belt cover mounting locations&'.(l engine ;$ /<$ //$ /1$ /3$ /6$ /7$ /8$ In tall the ti'ing "elt #over$ In tall the engine 'ount "ra#+et$ In tall the right engine 'ount$ Re'ove the floor )a#+ fro' under the vehi#le$ In tall the #ran+ haft da'&er$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ In tall the right inner &la h hield$ Re#onne#t the negative "attery #a"le$

3$<L Engine

Timing belt cover mounting detail&*.+) engine Cli#+ to enlarge /$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt $ Re'ove the engine 'ount in ulator fro' the engine u&&ort "ra#+et$ Re'ove the engine u&&ort "ra#+et$ Re'ove the #ran+ haft &ulley and tor ional da'&er$ Re'ove the ti'ing "elt #over $

To install: 6$ 7$ 8$ 9$ In tall the ti'ing "elt #over $ In tall the engine u&&ort "ra#+et$ Tighten the u&&ort "ra#+et 'ounting "olt to 37 ft$ l" $ ?69 N'@$ In tall the engine 'ount in ulator! tor ional da'&er and #ran+ haft &ulley $ In tall the a##e ory drive "elt and ad)u t the' to the &ro&er ten ion$ Re#onne#t the negative "attery #a"le$

Ti'ing Chain Cover
REMOVAL & INSTALLATION
3$3L and 3$:L Engine

Install the new oil seal with the installation tool !&(AA'&*.*) and *.,) engines

"emove these four engine brac-et fasteners&*.*) and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ If re'oving the ti'ing #hain! turn the #ran+ haft and &o ition the engine o the No$ / &i ton i at T2C on the #o'&re ion tro+e ?firing &o ition@$

2i #onne#t the negative "attery #a"le$ 2rain the engine #oolant$ Su&&ort the engine %ith a floor )a#+ and re'ove the right engine 'ount$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil$ Re'ove the oil &an and oil &u'& &i#+4u& tu"e$ If ne#e ary! re'ove the tran a*le in &e#tion #over$ 8$ Re'ove the right front %heel and inner fender &la h hield$ 9$ Re'ove the a##e ory drive "elt$ :$ Re'ove the air #onditioning #o'&re or and et a ide$ Re'ove A-C #o'&re or 'ounting "ra#+et$ ;$ Re'ove the #ran+ haft &ulley "olt and re'ove the &ulley u ing a uita"le &uller$ /<$ Re'ove the idler &ulley fro' the engine "ra#+et and re'ove the "ra#+et$ //$ Re'ove the #a' en or fro' the ti'ing #hain #over$

/1$ >n"olt and re'ove the ti'ing #hain #over fro' the engine$ Ma+e ure the oil &u'& inner rotor doe not fall out$

To remove the timing chain cover loosen the seven fasteners&*.*) and *.,) engines

Timing chain case cover gas-ets and 7&rings&*.*) and *.,) engines Cli#+ to enlarge /3$ Re'ove the #ran+ haft oil eal fro' the #over$ The eal 'u t "e re'oved fro' the #over %hen in talling to en ure &ro&er oil &u'& engage'ent$ The eal i in talled fro' the front AATER the ti'ing #hain front #over i #o'&letely in talled a outlined "elo%$

To install: /6$ > ing a ne% ga +et! in tall the ti'ing #hain #over to the engine$ 2O NOT adhere the ne% ga +et to the #over$ Ma+e ure the lo%er edge of the ga +et i flu h to <$<1< in$ ?<$7<''@ &a t the lo%er edge of the #over$ /7$ If ne#e ary! rotate the #ran+ haft o the oil &u'& drive flat are verti#al and &o ition the oil &u'& rotor o it 'ating flat are in the a'e &o ition$ Ma+e #ertain that the oil &u'& i engaged onto the #ran+ haft "efore &ro#eeding! or evere engine da'age %ill re ult$ In tall the atta#hing "olt and tor,ue to 1< ft$ l" $ ?19 N'@$ /8$ > e tool C46;;1 or e,uivalent eal driver to in tall the #ran+ haft oil eal$ /9$ In tall the #ran+ haft &ulley$ /:$ In tall the engine "ra#+et and tor,ue the "olt to 6< ft$ l" $ ?76 N'@$ In tall the idler &ulley to the engine "ra#+et$ /;$ In tall the #a' en or! fir t #lean off the old &a#er fro' the en or fa#e #o'&letely$ In &e#t the O4ring for da'age and re&la#e if ne#e ary$ A ne% &a#er 'u t "e atta#hed to the #a' en or! &rior to in tallation$ If a ne% &a#er i not u ed! engine &erfor'an#e %ill "e affe#ted$ Oil the O4ring lightly and &u h the en or into it "ore in the ti'ing #a e #over until #onta#t i 'ade %ith the #a' ti'ing &ro#+et$ Hold in thi &o ition and tighten it to /<: in#h l" $ ?/1 N'@$ 1<$ Re#onne#t the en or #onne#tor to the %iring harne #onne#tor$ 0o ition the %iring harne a%ay fro' the a##e ory drive "elt$ 1/$ In tall the air #onditioning #o'&re or and 'ounting "ra#+et$ 11$ In tall the drive "elt$ 13$ In tall the inner &la h hield and the %heel$ Tor,ue the %heel lug nut ! in a tar &attern! to ;7 ft$ l" $ ?/1; N'@$ 16$ In tall the oil &an %ith a ne% ga +et$ Tor,ue the oil &an "olt to /<7 in#h l" $ ?/1 N'@$ 17$ In tall the 'otor 'ount$ 18$ Refill the #ooling y te' to the #orre#t level %ith a 7<-7< 'i*ture of #lean! fre h ethylene gly#ol antifree5e and %ater$ 19$ Aill the engine %ith the &ro&er a'ount and ty&e of #lean engine oil$ 1:$ Re#onne#t the negative "attery #a"le$ Road te t the vehi#le and #he#+ for lea+ $

Ti'ing (elt and S&ro#+et
REMOVAL & INSTALLATION
1$6L Engine

!amshaft and cran-shaft timing mar-s for '.() engine

To loc- the timing belt tensioner, be sure to fully insert the smaller 1llen? wrench into the tensioner as shown& '.() engine

5ou may need "1B scan tool to perform the crankshaft and camshaft relearn alignment procedure. /$ 1$ 3$ 6$ 7$ 8$ 9$ :$ 2i #onne#t the negative "attery #a"le$ Re'ove the right inner &la h hield$ Re'ove the a##e ory drive "elt $ Re'ove the #ran+ haft da'&er$ Re'ove the right engine 'ount$ 0la#e a floor )a#+ under the engine to u&&ort it %hile the engine 'ount i re'oved$ Re'ove the engine 'ount "ra#+et$ Re'ove the ti'ing "elt #over$

This is an interference engine. "o not rotate the crankshaft or the camshafts after the timing elt has een removed. "amage to the valve components may occur. Before removing the timing elt, always align the timing marks. ;$ Align the ti'ing 'ar+ of the ti'ing "elt &ro#+et to the ti'ing 'ar+ on the rear ti'ing "elt #over and oil &u'& #over$ Loo en the ti'ing "elt ten ioner "olt $

/<$ Re'ove the ti'ing "elt and the ten ioner$ //$ If ne#e ary! re'ove the #a' haft ti'ing "elt &ro#+et $ /1$ If ne#e ary! re'ove the #ran+ haft ti'ing "elt &ro#+et u ing re'oval tool No$ 89;3 or e,uivalent$ /3$ 0la#e the ten ioner into a oft4)a%ed vi e to #o'&re the ten ioner$ /6$ After #o'&re ing the ten ioner! in ert a &in ?7-86 in$ AllenC %ren#h %ill al o %or+@ into the &lunger ide hole to retain the &lunger until in tallation$

Timing belt installation detail&'.() engine 9notice the camshaft alignment: Cli#+ to enlarge

The upper sproc-ets should be held in place with the special tool for removal and installation To install:

/7$ If ne#e ary! u ing tool No$ 89;1 or e,uivalent! to in tall the #ran+ haft ti'ing "elt &ro#+et onto the #ran+ haft$ /8$ If ne#e ary! in tall the #a' haft &ro#+et onto the #a' haft $ In tall and tighten the #a' haft &ro#+et "olt to 97 ft$ l" $ ?/</ N'@$ /9$ Set the #ran+ haft &ro#+et to To& 2ead Center ?T2C@ "y aligning the not#h on the &ro#+et %ith the arro% on the oil &u'& hou ing$ /:$ Set the #a' haft to align the ti'ing 'ar+ on the &ro#+et $ /;$ Move the #ran+ haft to /-1 not#h "efore T2C$ 1<$ In tall the ti'ing "elt tarting at the #ran+ haft! then around the %ater &u'& &ro#+et! idler &ulley! #a' haft &ro#+et and around the ten ioner &ulley$ 1/$ Move the #ran+ haft &ro#+et to T2C to ta+e u& the "elt la#+$ 11$ In tall the ten ioner on the engine "lo#+ "ut do not tighten$ 13$ > ing a tor,ue %ren#h on the ten ioner &ulley! a&&ly 17< in#h l" $?1: N'@ of tor,ue to the ten ioner &ulley$ 16$ .ith tor,ue "eing a&&lied to the ten ioner &ulley! 'ove the ten ioner u& again t the ten ioner &ulley "ra#+et and tighten the fa tener to 13 ft$ l" $?3/ N'@$ 17$ Re'ove the ten ioner &lunger &in! the ten ion i #orre#t %hen the &lunger &in #an "e re'oved and rein erted ea ily$

WARNING
If any binding is felt when adjusting the timing belt tension by turning the cran-shaft, .TO6turning the engine, because the pistons may be hitting the valves. 18$ Rotate the #ran+ haft t%o revolution and re#he#+ the ti'ing 'ar+ $ .ait everal 'inute and then re#he#+ that the &lunger &in #an ea ily "e re'oved and in talled$ 19$ In tall the front ti'ing "elt #over$ 1:$ In tall the engine 'ount "ra#+et$ 1;$ In tall the right engine 'ount$ 3<$ Re'ove the floor )a#+ fro' under the vehi#le$ 3/$ In tall the #ran+ haft da'&er and tighten it to /<7 ft$ l" $ ?/61 N'@$ 31$ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 33$ In tall the right inner &la h hield$ 36$ Re#onne#t the negative "attery #a"le$ 37$ 0erfor' the #ran+ haft and #a' haft relearn align'ent &ro#edure u ing the 2R( #an tool or e,uivalent$

3$<L Engine

.xploded view of the timing belt and sproc-et assembly&*.+) engine Cli#+ to enlarge

3ar- the direction of travel for the timing belt for correct installation

Turn the center tensioner pulley bolt until the timing belt has enough slac- ...

... then slide the timing belt off of the camshaft sproc-ets The timing belt can be inspected by removing the upper front outer timing belt cover. 5or-ing on any engine 9especially overhead camshaft engines: re%uires much care be given to valve timing. It is good practice to set the engine up at T2! /o. @ cylinder firing position before beginning wor-. $erify that all timing mar-s on the cran-shaft and camshaft sproc-ets are properly aligned before removing the timing belt and starting camshaft service. This serves as a point of reference for all wor- that follows. $alve timing is very important and engine damage will result if the wor- is incorrect. /$ 1$ 3$ 6$ 2i #onne#t the negative "attery #a"le$ Re'ove the a##e ory drive "elt $ Re'ove the engine 'ount in ulator fro' the engine u&&ort "ra#+et$ Re'ove the engine u&&ort "ra#+et$ Re'ove the #ran+ haft &ulley and tor ional da'&er$ Re'ove the ti'ing "elt #over $ Rotate the #ran+ haft until the &ro#+et ti'ing 'ar+ are aligned$ The #ran+ haft &ro#+et ti'ing 'ar+ hould align %ith the oil &u'& ti'ing 'ar+$ The rear #a' haft &ro#+et ti'ing 'ar+ hould align %ith the generator "ra#+et ti'ing 'ar+ and the front #a' haft &ro#+et ti'ing 'ar+ hould align %ith the inner ti'ing "elt #over ti'ing 'ar+$ If the "elt i to "e reu ed! 'ar+ the dire#tion of rotation on the "elt for in tallation referen#e$ Loo en the ti'ing "elt ten ioner "olt and re'ove the ti'ing "elt$ If ne#e ary! re'ove the ti'ing "elt ten ioner$ Re'ove the #ran+ haft &ro#+et flange hield and #ran+ haft &ro#+et$ Hold the #a' haft &ro#+et u ing &anner tool M(;;<997 or e,uivalent! and re'ove the #a' haft &ro#+et "olt and %a her$ Re'ove the #a' haft &ro#+et$

7$ 8$ 9$ :$ ;$

To install: /<$ In tall the #a' haft &ro#+et on the #a' haft %ith the retaining "olt and %a her$ Hold the #a' haft &ro#+et u ing &anner tool M(;;<997 or e,uivalent! and tighten the "olt to 9< ft$ l" $ ?;7 N'@$

//$ In tall the #ran+ haft &ro#+et$ /1$ If re'oved! in tall the ti'ing "elt ten ioner and ten ioner &ring$ Hoo+ the &ring u&&er end to the %ater &u'& &in and the lo%er end to the ten ioner "ra#+et %ith the hoo+ out$ /3$ Turn the ti'ing "elt ten ioner #ounter#lo#+%i e full travel in the ad)u t'ent lot and tighten the "olt to te'&orarily hold it in thi &o ition$ /6$ Rotate the #ran+ haft &ro#+et until it ti'ing 'ar+ i aligned %ith the oil &u'& ti'ing 'ar+$ /7$ Rotate the rear #a' haft &ro#+et until it ti'ing 'ar+ i aligned %ith the ti'ing 'ar+ on the generator "ra#+et$ /8$ Rotate the front ?radiator ide@ #a' haft &ro#+et until it 'ar+ i aligned %ith the ti'ing 'ar+ on the inner ti'ing "elt #over$ /9$ In tall the ti'ing "elt on the #ran+ haft &ro#+et %hile +ee&ing the "elt tight on the ten ion ide$ If the original elt is rotational direction. eing reused, e sure to install it in the same

/:$ 0o ition the ti'ing "elt over the front #a' haft &ro#+et ?radiator ide@$ Ne*t! &o ition the "elt under the %ater &u'& &ulley! then over the rear #a' haft &ro#+et and finally over the ten ioner$

WARNING
If any binding is felt when adjusting the timing belt tension by turning the cran-shaft, .TO6turning the engine, because the pistons may be hitting the valves.

"ent or borrow the special tool to hold the camshaft sproc-ets steady ...

... while loosening the center retaining bolt on the camshaft pulley, then ...

... remove the camshaft sproc-et from the end of the camshaft

Timing belt tensioner and spring positions

Timing belt routing and timing mar- locations Cli#+ to enlarge /;$ A&&ly rotating for#e in the o&&o ite dire#tion to the front #a' haft &ro#+et ?radiator ide@ to #reate ten ion on the ti'ing "elt ten ion ide$ Che#+ that all ti'ing 'ar+ are aligned$ 1<$ In tall the #ran+ haft &ro#+et flange$ 1/$ Loo en the ten ioner "olt and allo% the ten ioner &ring to ten ion the "elt$ 11$ Rotate the #ran+ haft t%o full turn in a #lo#+%i e dire#tion$ Turn the #ran+ haft 'oothly and in a #lo#+%i e dire#tion only$ 13$ Again line u& the ti'ing 'ar+ $ If all 'ar+ are aligned! tighten the ten ioner "olt to 17< in#h l" $ ?1: N'@$ Other%i e re&eat the in tallation &ro#edure$ 16$ In tall the ti'ing "elt #over $ In tall the engine u&&ort "ra#+et$ Tighten the u&&ort "ra#+et 'ounting "olt to 37 ft$ l" $ ?69 N'@$ 17$ In tall the engine 'ount in ulator! tor ional da'&er and #ran+ haft &ulley $ Tighten the #ran+ haft &ulley "olt to //1 ft$ l" $ ?/7/ N'@$ 18$ In tall the a##e ory drive "elt and ad)u t the' to the &ro&er ten ion$ 19$ Re#onne#t the negative "attery #a"le$ 1:$ Run the engine and #he#+ for &ro&er o&eration$ Road te t the vehi#le$

in &e#tion WARNING
Timing belt maintenance is extremely importantB 1ll /eon models utili<e an interference&type, non&free&wheeling engine. If the timing belt brea-s, the valves in the cylinder head may stri-e the pistons, causing potentially serious 9also time&consuming and expensive: engine damage. The recommended replacement interval for the timing belt is @+',+++ miles 9@C*,+++-m:, or sooner. Dou would be wise to chec- the belt periodically to ma-e sure it has not become damaged or worn. 6enerally spea-ing, a severely worn belt may cause engine performance to drop dramatically, but a damaged belt 9which could give out suddenly: may not give as much warning. In general, any time the engine timing cover9s: is9are: removed you should inspect the belt for premature parting, severe crac-s or missing teeth. 1lso, an access plug or cover is provided in the upper portion of the timing cover so that camshaft timing can be chec-ed without cover removal. If timing is found to be off, cover removal and further belt inspection or replacement is necessary.

!hec- for premature parting of the belt

!hec- if the teeth are crac-ed or damaged

)oo- for noticeable crac-s or wear on the belt face

Dou may only have damage on one side of the beltE if so, the guide could be the culprit

Foreign materials can get in between the teeth and cause damage

Ti'ing Chain and Gear
REMOVAL & INSTALLATION
3$3L and 3$:L Engine

Timing mar- alignment for *.* and *.,) engines /$ 1$ 3$ 6$ 7$ Turn the #ran+ haft and &o ition the engine o the No$ / &i ton i at T2C on the #o'&re ion tro+e ?firing &o ition@$

2i #onne#t the negative "attery #a"le$ 2rain the #oolant$ Su&&ort the engine %ith a floor )a#+ and re'ove the right engine 'ount$ Rai e and afely u&&ort the vehi#le$ 2rain the engine oil$ Re'ove the oil &an and oil &u'& &i#+4u& tu"e$ If ne#e ary! re'ove the tran a*le in &e#tion #over$ 8$ Re'ove the right front %heel and inner fender &la h hield$ 9$ Re'ove the a##e ory drive "elt$ :$ Re'ove the air #onditioning #o'&re or and et a ide$ Re'ove A-C #o'&re or 'ounting "ra#+et$ ;$ Re'ove the #ran+ haft &ulley$ /<$ Re'ove the idler &ulley fro' the engine "ra#+et and re'ove the "ra#+et$

//$ Re'ove the #a' haft &o ition en or$ /1$ Re'ove the ti'ing #hain #over fro' the engine$ Ma+e ure the oil &u'& inner rotor doe not fall out$ Re'ove the 3 O4ring fro' the #oolant &a age and the oil &u'& outlet$ /3$ Re'ove the #a' haft &ro#+et atta#hing #u& %a her and re'ove the ti'ing #hain %ith "oth &ro#+et atta#hed$ Re'ove the ti'ing #hain nu""er$ /6$ Re'ove the #ran+ haft &ro#+et u ing a uita"le &uller tool$

3easuring timing chain stretch and wear&*.* and *.,) engines To install: /7$ A e'"le the ti'ing #hain and &ro#+et $

/8$ Turn the #ran+ haft and #a' haft to line u& %ith the +ey %ay lo#ation of the &ro#+et $ /9$ Slide "oth &ro#+et over their re &e#tive haft and u e a traightedge to #onfir' align'ent$ /:$ In tall the #u& %a her and #a' haft "olt$ Tor,ue the "olt to 6< ft$ l" $ ?76 N'@$ /;$ Che#+ #a' haft end4&lay$ The &e#ifi#ation %ith a ne% &late i <$<<74<$</1 in$ ?<$</194<$3<6''@ and <$</1 in$ ?<$3/<''@ 'a*i'u' %ith a u ed &late$ Re&la#e the thru t &late if not %ithin &e#ifi#ation $ 1<$ In tall the ti'ing #hain nu""er$ 1/$ Clean all &art %ell$ Thoroughly #lean and dry the ga +et 'ating urfa#e $ In tall ne% O4ring to the "lo#+$ 11$ Re'ove the #ran+ haft oil eal fro' the #over$ The eal 'u t "e re'oved fro' the #over %hen in talling to en ure &ro&er oil &u'& engage'ent$ The eal i in talled fro' the front AATER the ti'ing #hain front #over i #o'&letely in talled a outlined "elo%$ 13$ > ing a ne% ga +et! in tall the #hain #a e #over to the engine$ 2O NOT adhere the ne% ga +et to the #over$ Ma+e ure the lo%er edge of the ga +et i flu h to <$<1< in$ ?<$7<''@ &a t the lo%er edge of the #over$ 16$ If ne#e ary! rotate the #ran+ haft o the oil &u'& drive flat are verti#al and &o ition the oil &u'& rotor o it 'ating flat are in the a'e &o ition$ Ma+e #ertain that the oil &u'& i engaged onto the #ran+ haft "efore &ro#eeding! or evere engine da'age %ill re ult$ In tall the atta#hing "olt and tor,ue to 1< ft$ l" $ ?19 N'@$ 17$ > e tool C46;;1 or e,uivalent eal driver to in tall the #ran+ haft oil eal$ 18$ In tall the #ran+ haft &ulley u ing a "olt a&&ro*i'ately 8 in$ ?/7<''@ long and thru t "earing and %a her &late$ Ma+e ure the &ulley "otto' out on the #ran+ haft eal dia'eter$ In tall the "olt and tor,ue to 6< ft$ l" $ ?76 N'@$

19$ In tall the engine "ra#+et and tor,ue the "olt to 6< ft$ l" $ ?76 N'@$ In tall the idler &ulley to the engine "ra#+et$ 1:$ In tall the #a' haft &o ition en or$ 1;$ In tall the air #onditioning #o'&re or and 'ounting "ra#+et$ 3<$ In tall the drive "elt$ 3/$ In tall the inner &la h hield and the %heel$ Tor,ue the %heel lug nut ! in a tar &attern! to ;7 ft$ l" $ ?/1; N'@$ 31$ In tall the oil &an$ 33$ In tall the 'otor 'ount$ 36$ Refill the #ooling y te' to the #orre#t level %ith a 7<-7< 'i*ture of #lean! fre h ethylene gly#ol antifree5e and %ater$ 37$ Aill the engine %ith the &ro&er a'ount and ty&e of #lean engine oil$ 38$ Re#onne#t the negative "attery #a"le$ Road te t the vehi#le and #he#+ for lea+ $

Ca' haft! (earing and Lifter
REMOVAL & INSTALLATION CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1$6L Engine

!amshaft bearing cap identification&'.() engine

!amshaft bearing cap removal se%uence&'.() engine Cli#+ to enlarge This engine uses a 2ual 7ver 8ead !amshaft 9278!: (&valves per cylinder crossflow aluminum cylinder head. The valves are actuated by roller cam followers which pivot on stationary hydraulic valve lash adjusters. !are must be ta-en to ensure all valve timing mar-s align after cylinder head and valvetrain service. /$ 1$ 3$ 6$ 7$ 0ro&erly relieve the fuel y te' &re ure$

8$ 9$ :$ ;$

2i #onne#t the negative "attery #a"le$ La"el and di #onne#t the &ar+ &lug %ire fro' the &ar+ &lug $ Re'ove the ignition #oil &a#+ and &ar+ &lug %ire $ Re'ove the #ylinder head #over retaining fa tener and re'ove the #ylinder head #over fro' the #ylinder head$ 2i #ard the old #ylinder head #over ga +et$ Re'ove the ground tra&$ Re'ove the ti'ing "elt #over ! ti'ing "elt and #a' haft &ro#+et $ Ta+e note that the #a' haft "earing #a& are nu'"ered for #orre#t lo#ation during in tallation$ Re'ove the outer "earing #a& fir t$ Loo en! "ut do not re'ove! the #a' haft "earing #a& retaining fa tener in the #orre#t e,uen#e$ 0erfor' thi te& on one #a' haft at a ti'e$

!amshaft bearing cap tightening se%uence&'.() engine

!amshaft bearing cap sealant application&'.() engine /<$ Tag the #a' haft for inta+e and e*hau t! if they are to "e reu ed! for later in tallation$ The #a' haft are not inter#hangea"le$ Re'ove the #a' haft "earing #a& and the #a' haft $ //$ Re'ove the #a' haft follo%er $ Any #o'&onent that are to "e reu ed 'u t "e in talled in their original lo#ation $ > e #are to identify and 'ar+ the &o ition of any re'oved valvetrain #o'&onent o they 'ay "e rein talled #orre#tly$ /1$ In &e#t the #a' haft "earing oil feed hole in the #ylinder head for #logging$ In &e#t the #a' haft "earing )ournal for %ear or #oring$ Che#+ the #a' urfa#e for a"nor'al %ear and da'age$ A vi i"le %orn groove in the roller &ath or on the #a' lo"e i #au e for re&la#e'ent$ To install: /3$ Thoroughly #lean the #a' haft and related &art $ /6$ The #a' haft end4&lay hould "e #he#+ed u ing the follo%ing &ro#edureB /$ Oil the #a' haft )ournal and in tall the #a' haft .ITHO>Tthe #a' follo%er a e'"lie $ In tall the rear #a' #a& and tighten to 17< in#h l" $ ?1: N'@$ 1$ Carefully &u h the #a' haft a far rear%ard a it %ill go$ 3$ Set u& a dial indi#ator to "ear again t the front of the #a' haft ?the &ro#+et end@$ Fero the indi#ator$ 6$ Move the #a' haft for%ard a far a it %ill go$ Read the dial indi#ator$ End4&lay &e#ifi#ation i <$<<14<$</< in$ ?<$<74<$/7''@$ 7$ If e*#e ive end4&lay i &re ent! in &e#t the #ylinder head and #a' haft for %earE re&la#e if ne#e ary$ /7$ If ati fied %ith the fit and #ondition of the #a' haft ! re'ove the #a' haft for in tallation of the #a' follo%er $ /8$ The hydrauli# valve la h ad)u ter are in ide the roller #a' follo%er $ En ure they are #lean! %ell4lu"ri#ated %ith #lean engine oil and &ro&erly &o itioned$

In tall the #a' follo%er in their original &o ition on the hydrauli# la h ad)u ter and valve te'$

WARNING
To avoid valve&to&piston contact, be sure /O/7of the pistons are at Top 2ead !enter 9T2!: when installing the camshafts. /9$ Lu"ri#ate the #a' haft "earing )ournal and #a' follo%er %ith #lean engine oil and in tall the #a' haft $ In tall right and left #a' haft "earing #a& No$ 1 through No$ 7 and right ide No$ 8$ Tighten the M8 fa tener to /<7 in#h l" $ ?/1 N'@ in #orre#t e,uen#e$ /:$ A&&ly Mo&arC Ga +et Ma+er or e,uivalent ealer to the No$ / and left ide No$ 8 "earing #a& $ In tall the "earing #a& and tighten the M: fa tener to 17< in#h l" $ ?1: N'@$ The end #a& 'u t "e in talled "efore the eal 'ay "e in talled$ /;$ In tall the #a' haft end eal $ 1<$ In tall the #a' haft &ro#+et ! if re'oved$ In tall the ti'ing "elt u ing #are to "e ure all ti'ing 'ar+ are &ro&erly aligned$ In tall the ti'ing "elt #over $

WARNING
$erify that all timing mar-s are correct. If the timing belt or sproc-ets are incorrectly installed, engine damage will occur. Ta-e time to be sure all timing mar-s are correctly aligned. 1/$ Clean the #ylinder head #over and #ylinder head ga +et rail ?'ating urfa#e @$ Ma+e #ertain the rail are flat$ 11$ In tall ne% #ylinder head #over ga +et $ > e #areE 2O NOT allo% oil or olvent to #onta#t the ti'ing "elt a they #an deteriorate the ru""er and #au e tooth +i&&ing$ A&&ly Mo&arC Sili#one Ru""er Adhe ive Sealant! or e,uivalent! at the #a' haft #a& #orner and at the to& edge of the /-1 round eal$ Inspect the spark plug well seals for cracking and8or swelling, and replace if necessary. 13$ In tall the #ylinder head #over a e'"ly to the head and tighten the fa tener in e,uen#e u ing the follo%ing three u" te& B Tighten all #ylinder head #over fa tener to 6< in#h l" $ ?6$7 N'@$ 1$ Tighten all fa tener to :< in#h l" $ ?; N'@$ 3$ Tighten all fa tener to /<7 in#h l" $ ?/1 N'@$ 16$ In tall the ignition #oil &a#+ and #onne#t the &ar+ &lug %iring to the #orre#t &ar+ &lug $ Tighten the #oil &a#+ retaining fa tener to /<7 in#h l" $ ?/1 N'@$ 17$ Re#onne#t the ground tra&$ 18$ En ure all va#uu' line and re'aining %iring have "een re#onne#ted$ To remove any dirt particles that may have fallen in the engine, an oil and filter change is recommended. 19$ Conne#t the negative "attery #a"le and te t run the vehi#le$ Che#+ for lea+ and for &ro&er o&eration$ /$

3$<L Engine

1fter the timing belt and camshaft sproc-et are removed, loosen the roc-er arm hold&down bolts ...

...then remove the roc-er arm cover from the cylinder head 5or-ing on any engine, but especially overhead camshaft engines, re%uires much care be given to valve timing. It is good practice to set the engine up at T2! /o. @ cylinder firing position. $erify that all timing mar-s on the cran-shaft and camshaft sproc-ets are properly aligned before removing the timing belt and beginning camshaft service. This serves as a point of reference for all wor- that follows. $alve timing is very important and engine damage will result if the wor- is incorrect. /$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Re'ove the air #leaner a e'"ly$ 2i #onne#t and la"el the &ar+ &lug %ire $ Re'ove the a##e ory drive "elt ! if ne#e ary$

"emove the upper timing belt rear cover retaining bolts ...

... and lift the rear cover from the camshaft

The distributor drive housing must be removed by unscrewing the mounting bolts ...

... and simply pulling off of the end of the cylinder head 6$ Move a%ay any %iring harne e for ea ier a##e to the rear valve #over$ 2i #onne#t and la"el any va#uu' ho e re,uired for ea ier re'oval of the valve #over $ Re'ove the valve #over fro' the vehi#le$ Re'ove the ti'ing "elt$ Re'ove the #a' haft ti'ing "elt &ro#+et $ In tall auto la h ad)u ter retainer M2;;:663 or e,uivalent on the ro#+er ar' $ If re'oving the right ide ?front@ #a' haft! re'ove the di tri"utor ada&ter$ Re'ove the #a' haft "earing #a& ! "ut do not re'ove the "olt fro' the #a& $

7$ 8$ 9$ :$ ;$

3a-e sure to remove the used 7&ring and install a new one on the drive housing for assembly

!ompletely loosen the roc-er arm shaft hold&down bolts

)ift the roc-er arm shaft assembly off of the cylinder head 9do not lose the lash adjusters:

)ift the camshaft out of the cylinder head /<$ Re'ove the ro#+er ar' ! ro#+er haft and "earing #a& ! a an a e'"ly$

2se care not to mi3 rocker arms and shafts. The oil holes are different in the shafts and each must e returned to its original location or the engine overhead will not e lu ricated. //$ Re'ove the #a' haft fro' the #ylinder head$ /1$ In &e#t the "earing )ournal on the #a' haft! #ylinder head and "earing #a& $ To install: /3$ Clean all &art %ell$ 0ay &arti#ular attention to the oil feed hole in the #ylinder head! #he#+ing for #logging$ If the #a' haft are to "e reu ed! #he#+

%ith a 'i#ro'eter$ Mea ure the #a' height and re&la#e if out of li'it$ Standard value i /$816 in$ ?6/$17''@ and %ear li'it i /$8<6 in$ ?6<$97''@$ /6$ Lu"ri#ate the #a' haft )ournal and #a' haft %ith #lean engine oil and in tall the #a' haft in the #ylinder head$ /7$ Align the #a' haft "earing #a& %ith the arro% 'ar+ ?de&ending on #ylinder nu'"er @ and in nu'eri#al order$ /8$ A&&ly ealer at the end of the "earing #a& and in tall the a e'"ly$ /9$ Tighten the "earing #a& "olt ! in the follo%ing e,uen#eB No$ 3! No$ 1! No$ / and No$ 6 to :7 in#h l" $ ?/< N'@$

3a-e sure to remove and discard the used rear and front camshaft seals

5hen installing the roc-er shafts ma-e sure the arrows point in the same direction as the arrows

on the cylinder heads

2istributor drive, front oil seal and 7&ring

!ylinder head and camshaft components Cli#+ to enlarge /:$ Re&eat the e,uen#e! in#rea ing tor,ue to /:< in#h l" $ ?1< N'@$ /;$ In tall the di tri"utor ada&ter! if it %a re'oved$ 1<$ Re'ove the la h ad)u ter retainer $ In tall the #a' haft ti'ing "elt &ro#+et and ti'ing "elt$ 1/$ In tall the valve #over and ne% ga +et $ Tighten the valve #over retaining "olt to :: in#h l" $ ?/< N'@$ 11$ Re#onne#t all va#uu' ho e that %ere re'oved during the re'oval &ro#edure$ (e ure they are all re#onne#ted to the #orre#t va#uu' line $ 13$ 0o ition the %iring harne e "a#+ to their original lo#ation $ In tall the a##e ory drive "elt and ad)u t to the &ro&er ten ion$ 16$ Re#onne#t the &ar+ &lug %ire to the #orre#t &ar+ &lug $ 17$ In tall the air #leaner a e'"ly$ Re#onne#t the negative "attery #a"le$ 18$ Run the engine and #he#+ for lea+ and &ro&er engine o&eration$

3$3L And 3$:L Engine

The camshaft is held in place by thrust plate retained by two bolts &*.*) and *.,) engines Cli#+ to enlarge /$ 1$ 3$ 6$ 7$ 8$ Relieve the fuel y te' &re ure$ 2i #onne#t the negative "attery #a"le$

Re'ove the engine fro' the vehi#le$ Re'ove the inta+e 'anifold! #ylinder head ! ti'ing #hain #over and ti'ing #hain fro' the engine$ Re'ove the ro#+er ar' and haft a e'"lie $ La"el and re'ove the &u hrod and lifter $ Re'ove the #a' haft thru t &late$ In tall a long "olt into the front of the #a' haft to fa#ilitate it re'oval$ Re'ove the #a' haft "eing #areful not to da'age the #a' "earing %ith the #a' lo"e $

To install: 9$ :$ ;$ In tall the #a' haft to %ithin 1 in$ of it final in tallation &o ition$ In tall the #a' haft thru t &late and t%o "olt $ Tighten the "olt to /< ft$ l" $ ?/1 N'@$ 0la#e "oth #a' haft and #ran+ haft gear on the "en#h %ith the ti'ing 'ar+ on the e*a#t i'aginary #enter line through "oth gear "ore a they are in talled on the engine$ 0la#e the ti'ing #hain around "oth &ro#+et $ Turn the #ran+ haft and #a' haft o the +ey line u& %ith the +ey %ay in the gear %hen the ti'ing 'ar+ are in &ro&er &o ition$ Slide "oth gear over their re &e#tive haft and u e a traight edge to #he#+ ti'ing 'ar+ align'ent$ Mea ure #a' haft end4&lay$ If not %ithin &e#ifi#ation ! re&la#e the thru t &late$ If the #a' haft %a not re&la#ed! lu"ri#ate and in tall the lifter in their original lo#ation $ If the #a' haft %a re&la#ed! ne% lifter 'u t "e u ed$ In tall the &u hrod and ro#+er haft a e'"lie $ In tall the ti'ing #hain #over! #ylinder head and inta+e 'anifold$ In tall the engine in the vehi#le$ .hen everything i "olted in &la#e! #hange the engine oil and re&la#e the oil filter$

/<$ //$ /1$ /3$ /6$ /7$ /8$ /9$

If the camshaft or lifters have een replaced, add & pint of 9opar: crankcase conditioner, or e-uivalent when replenishing the oil to aid

in reak in. This mi3ture should e left in the engine for a minimum of (%% miles and drained at the ne3t normal oil change. /:$ Aill the radiator %ith #oolant$ /;$ Conne#t the negative "attery #a"le! et all ad)u t'ent to &e#ifi#ation and #he#+ for lea+ $

INS0ECTION
/$ 1$ 3$ 6$ 7$ 8$ In &e#t the #a' haft "earing )ournal for %ear or da'age$ In &e#t the #ylinder head and #he#+ oil return hole $ Che#+ the tooth urfa#e of the di tri"utor drive gear teeth of the right #a' haft for %ear or da'age$ Che#+ "oth #a' haft urfa#e for %ear or da'age$ Re'ove the di tri"utor drive ada&tor eal$ Che#+ #a' haft lo"e height and re&la#e if out of li'it$ Standard value i /$8/ in$ ?6/''@$

Au*iliary ?Idler@ Shaft
REMOVAL & INSTALLATION
1$6L Engine
The '.() engine is e%uipped with ' balance shafts installed in a carrier mounted to the lower cran-case. These balance shafts interconnect through gears to rotate in opposite directions. The gears are powered by a short, cran-shaft&driven chain and rotate at ' times the speed of the cran-shaft. This will counterbalance certain reciprocating masses of the engine. 1n oil passage from the /o. @ main bearing cap through the balance shaft carrier support leg provides lubrication to the balance shafts. This passage directly supplies engine oil to the front bearings and internal machined passages in the shafts that routes engine oil from the front to the rear shaft bearing journals. 4lease note that this procedure re%uires removal of the timing belt. $alve train timing is critical to engine performance and to prevent engine damage. 5or- carefully and verify all timing mar-s as the engine is reassembled. /$ 1$ 3$ 2i #onne#t the negative "attery #a"le$

Re'ove the a##e ory drive "elt $ Refer to Section 1$ Re'ove the ti'ing "elt #over and ti'ing "elt! a outlined earlier in thi e#tion$ 6$ Rai e and afely u&&ort the vehi#le$ 7$ 0la#e a large drain &an under the oil &an drain &lug and drain the engine oil$ 8$ Re'ove the oil &u'& and oil &an$ 9$ Re'ove the "alan#e haft drive #hain #over$ :$ Re'ove the drive #hain guide and drive #hain ten ioner$ ;$ Re'ove the gear #over retaining tud ?dou"le ended to al o 'ount the drive #hain guide@$ /<$ Re'ove the "alan#e haft gear and #hain &ro#+et retaining #re% $ //$ Re'ove the drive #hain and #hain &ro#+et a e'"ly "y u ing 1 &ry"ar to %or+ the &ro#+et "a#+ and forth until it i re'oved fro' the #ran+ haft$ /1$ Re'ove the gear #over and "alan#e haft $

/3$ Re'ove the 6 "alan#e haft #arrier4to4#ran+#a e 'ounting "olt ! then e&arate the #arrier fro' the engine "ed&late$ To install: /6$ In tall the "alan#e haft into the #arrier and &la#e the #arrier into &ro&er &o ition again t the engine "ed&late$ In tall and tighten the 6 'ounting "olt to 6< ft$ l" $ ?76 N'@$ /7$ Rotate the "alan#e haft until "oth "alan#e haft +ey%ay are &ointed u& &arallel to the verti#al #enterline of the engine$ /8$ Rein tall the hort hu" drive gear onto the &ro#+et driven "alan#e haft and the long hu" gear onto the #hain driven haft$ On#e the gear are in talled onto the haft ! the gear and "alan#e haft +ey%ay 'u t "e u&! and gear align'ent dot &ro&erly 'e hed$

0alance shaft gear timing /9$ Rein tall the gear #over and retaining tud fa tener$ Tighten the dou"le ended retaining tud fa tener to /<7 in#h l" $ ?/1 N'@$ /:$ Rein tall the drive #hainG #ran+ haft &ro#+et$ (e ure to align the flat on the &ro#+et to the flat on the #ran+ haft! %ith the &ro#+et fa#ing front$

Install the cran-shaft sproc-et with a suitable driver tool /;$ Rotate the #ran+ haft until the No$ / #ylinder i at To& 2ead Center ?T2C@$ The ti'ing 'ar+ on the #hain &ro#+et hould align %ith the &arting line on the left ide of No$ / 'ain "earing #a&$

3aintain the proper balance shaft timing mar- alignment Cli#+ to enlarge 1<$ 0la#e the drive #hain around the #ran+ haft &ro#+et o the ni#+el &lated lin+ of the #hain i on the No$ / #ylinder ti'ing 'ar+ of the #ran+ haft &ro#+et$ 1/$ Rein tall the "alan#e haft &ro#+et into the drive #hain$ (e ure the ti'ing 'ar+ on the "alan#e haft &ro#+et ?yello% dot@ line u& %ith lo%er ni#+el &lated lin+ on the #hain$ 11$ .ith the +ey%ay of the "alan#e haft &ointing u& in the /1 oG#lo#+ &o ition! lide the "alan#e haft drive #hain &ro#+et onto the end of the "alan#e haft$ If ne#e ary to allo% for #learan#e! the "alan#e haft 'ay "e &u hed in lightly$ The lower nickel plated link, timing mark on the alance shaft sprocket, and arrow on the side of the gear cover should all line up when the alance shafts are properly timed. 13$ If the &ro#+et are ti'ed #orre#tly! in tall the "alan#e haft "olt and tighten to 17< in#h l" $ ?1: N'@$ It 'ay "e ne#e ary to &la#e a %ooden "lo#+ "et%een the #ran+#a e and #ran+ haft #ounter"alan#e to &revent #ran+ haft and gear rotation$ 16$ In tall the drive #hain ten ioner! "ut +ee& it loo e at thi &oint$ 17$ 0o ition the drive #hain guide onto the dou"le ended tud fa tener$ (e ure the ta" on the guide fit into the lot on the gear #over$ In tall the nut-%a her a e'"ly and tighten to /<7 in#h l" $ ?/1 N'@$

18$ 0la#e a hi' <$<3; in$ * 1$97 in$ ?/'' * 9<''@ long "et%een the ten ioner and #hain$ 0u h the ten ioner and hi' u& again t the #hain$ A&&ly &re ure of 7$748$8 l" $ dire#tly "ehind the ad)u t'ent lot to ta+e u& the la#+$ (e ure the #hain 'a+e hoe radiu #onta#t$ 19$ .ith the &re ure a&&lied! tighten the to& ten ioner ad)u t'ent "olt fir t! then the lo%er &ivot "olt$ Tighten the "olt to /<7 in#h l" $ ?/1 N'@$ Re'ove the hi' after tightening the "olt $ 1:$ In tall the #hain #over and tighten the #re% to /<7 in#h l" $ ?/1 N'@$ 1;$ In tall oil &u'& and oil &an$ 3<$ In tall the oil &an drain &lug and ga +et$ Tighten the drain &lug to 17 ft$ l" $ ?36 N'@$ 3/$ Lo%er the vehi#le$ 31$ In tall the ti'ing "elt and ti'ing "elt #over ! a de #ri"ed earlier in thi e#tion$ It i very i'&ortant that all valve ti'ing 'ar+ align &ro&erly! or engine da'age %ill re ult$ 33$ In tall the a##e ory drive "elt ! and ad)u t a ne#e ary$ 36$ Refill the engine %ith ne%! #lean engine oil to the &ro&er level$ An oil filter #hange i al o re#o''ended$ 37$ Re#onne#t the negative "attery #a"le$ Start the engine and #he#+ for lea+ $

Rear Main Seal
REMOVAL & INSTALLATION

"ear main seal installation using the appropriate tools&'.() engine /$ 1$ 3$ 2i #onne#t the negative "attery #a"le$ Re'ove the tran a*le$ Re'ove the fle*&late fro' the #ran+ haft$

WARNING

2o not let the prytool damage the sealing surface of the cran-shaft, or an oil lea- may result. 6$ Carefully &ry the oil eal out of the "ore %ith a flat4"laded &rytool$

To install:

"ear main seal installation using the appropriate tools&*.+) engine

Install the rear main seal using the appropriate seal driver&*.* and *.,) engines

1pply silicone sealant to the seal retainer before installation&*.+l engine

WARNING
To prevent seal damage, remove any burrs or scratches on the edge of the cran-shaft with (++ grit sandpaper before installing the seal. 7$ 8$ In tall the eal u ing the a&&ro&riate eal in tallation tool$ In tall the fle*&late and the tran a*le a e'"ly$

Aly%heel-Ale*&late
REMOVAL & INSTALLATION
The most common reason to replace the flexplate is bro-en teeth on the starter ring gear. 7n automatic transaxle vehicles, the tor%ue converter actually forms part of the flywheel. It is bolted to a thin flexplate which, in turn, is bolted to the cran-shaft. The flexplate also serves as the ring gear with which the starter pinion engages in engine cran-ing. The flexplate occasionally crac-sE the teeth on the ring gear may also brea-, especially if the starter is often engaged while the pinion is still spinning. The tor%ue converter and flexplate are separated, so the converter and transaxle can be removed together. /$ 1$ 3$ Re'ove the tran a*le fro' the vehi#le$ Aor 'ore infor'ation! refer to Section 7$ Su&&ort the fly%heel in a e#ure 'anner$ Mat#h'ar+ the fly%heel-fle*&late to the rear flange of the #ran+ haft$

Typical flywheel/flexplate installation Cli#+ to enlarge 6$ Re'ove the atta#hing "olt and &ull the fly%heel-fle*&late fro' the #ran+ haft$

To install: 7$ 8$ 9$ Clean the fly%heel-fle*&late atta#hing "olt ! the fly%heel-fle*&late and the rear #ran+ haft 'ounting flange$ 0o ition the fly%heel-fle*&late onto the #ran+ haft flange o that the 'at#h'ar+ align$ Coat the thread of the atta#hing "olt %ith Lo#titeC Thread Lo#+er 19/! or e,uivalent! to hel& en ure that the atta#hing "olt %ill not %or+ loo e$ In tall the "olt finger4tight$ Tighten the atta#hing "olt in a #ri #ro fa hion in 3 even te& to 8:49< ft$ l" $ ?;14;7 N'@$ In tall the tran a*le! a de #ri"ed in Se#tion 9$

:$ ;$

Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.

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