Special Tool(s)
SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-C) Adapter for 303-577 303-576 (T97T-6256-D) Extension, Torque Wrench 303-575 (T97T-6256-F) Holding Tool, Camshaft 303-577 (T97T-6303-C) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) or equivalent Tensioner, Timing Chain 303-571 (T97T-6K254-A) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
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Scheme 363
- Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-365365-S01832068132010070700000).
- NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
- If equipped, remove the nut and position the A/C hose aside.
- NOTE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of the engine. NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block, this positions the engine at TDC. Install the Crankshaft TDC Timing Tool.
- Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 to the RH cylinder head and, if necessary, tighten the 2 top clamp bolts to 10 Nm (89 lb-in).
- NOTE: The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. If necessary, using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, loosen the RH camshaft sprocket bolt.
- If necessary, loosen the top 2 Camshaft Sprocket Holding Tool clamp bolts.
- NOTE: The camshaft timing slots are off center. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft Holding Tool and the Adapter for 303-577 and install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head.
- Remove the 6 pushpins and the RH lower splash shield.
- Remove the RH hydraulic timing chain tensioner. Discard the washer.
- Install the Timing Chain Tensioner.
- NOTE: The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, tighten the bolts. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in). Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, tighten the camshaft bolt to 85 Nm (63 lb-ft). Calculate the correct torque wrench setting for the above torque. (Scheme 351)
- Remove the Timing Chain Tensioner.
- NOTE: Install a new washer on the tensioner. Install the RH hydraulic timing chain tensioner. Tighten to 44 Nm (32 lb-ft).
- Install the RH lower splash shield and the 5 pushpins.
- Remove the Camshaft Sprocket Holding Tool, the Adapter for 303-564, the Camshaft Holding Tool and the Adapter for 303-577 from the RH cylinder head.
- Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head and, if necessary, tighten the top 2 clamp bolts to 10 Nm (89 lb-in).
- If necessary, loosen the LH camshaft sprocket bolt.
- If necessary, loosen the top 2 clamp bolts on the Camshaft Sprocket Holding Tool to allow the camshaft sprocket to rotate freely.
- NOTE: The camshaft timing slots are off center. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft Holding Tool and the Adapter for 303-577 and install the Camshaft Holding Tool and the Adapter for 303-577 on the rear of the LH cylinder head.
- Remove the LH hydraulic timing chain tensioner. Discard the washer.
- Install the Timing Chain Tensioner.
- Tighten the bolts. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in). Tighten the LH camshaft bolt to 85 Nm (63 lb-ft).
- Remove the Timing Chain Tensioner.
- NOTE: Install a new washer on the tensioner. Install the LH hydraulic timing chain tensioner. Tighten to 44 Nm (32 lb-ft).
- Remove the Camshaft Sprocket Holding Tool, the Adapter for 303-564, the Camshaft Holding Tool and the Adapter for 303-577 from the LH cylinder head.
- Remove the Crankshaft TDC Timing Tool.
- If equipped, position the A/C hose and install the nut. Tighten to 20 Nm (177 lb-in).
- Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-365365-S01832068132010070700000).
Scheme 364
| Item | Part Number | Description |
|---|---|---|
| 1 | 9A758 | Accelerator cable |
| 2 | 9A825 | Speed control actuator cable (speed control equipped vehicles only) |
| 3 | 14A464 | Throttle Position (TP) sensor electrical connector (part of 12B637) |
| 4 | 13A506 | Wiring harness retainer (part of 12B637) |
| 5 | 14A464 | Idle Air Control (IAC) motor electrical connector (part of 12B637) |
ITEM DESCRIPTION
Scheme 365
| Item | Part Number | Description |
|---|---|---|
| 6 | 9E499 | EGR valve vacuum hose connector (part of 9E498) |
| 7 | 9E469 | Exhaust manifold-to-EGR valve tube |
| 8 | 9Y476 | Evaporative Emission (EVAP) purge valve-to-intake manifold hose |
| 9 | 14A464 | EGR vacuum regulator solenoid electrical connector (part of 12B637) |
| 10 | 9E499 | EGR vacuum regulator solenoid vacuum connector (part of 9E498) |
| 11 | 9E499 | Main vacuum hose connector (part of 9E498) |
| 12 | 160200 | Brake booster vacuum hose |
ITEM DESCRIPTION
Scheme 366
| Item | Part Number | Description |
|---|---|---|
| 13 | RH spark plug wires (part of 12280) | |
| 14 | RH spark plug wire retainer (part of 12280) | |
| 15 | 14A464 | Ignition coil electrical connector (part of 12B637) |
| 16 | 13A506 | Wiring harness retainer (part of 12B637) |
| 17 | Ignition coil bracket upper bolt (2 required) | |
| 18 | 14489 | Radio interference capacitor electrical connector (part of 12B637) |
| 19 | N802768 | Accelerator cable retainer |
| 20 | W500041 | Ignition coil bracket lower rear bolt |
| 21 | W500023 | Ignition coil bracket lower front bolt |
| 22 | 12257 | Ignition coil bracket |
ITEM DESCRIPTION
Scheme 367
| Item | Part Number | Description |
|---|---|---|
| 23 | N621906 | Wiring harness retainer nut |
| 24 | Wiring harness retainer (part of 12B637) | |
| 25 | 14A464 | PCM electrical connector (part of 12B637) |
| 26 | N806925 | Wiring harness ground wire stud bolt |
| 27 | 14463 | Wiring harness ground terminal (part of 12B637) |
ITEM DESCRIPTION
Scheme 368
| Item | Part Number | Description |
|---|---|---|
| 28 | Knock Sensor (KS) electrical connector (part of 12A699) | |
| 29 | 95479 | Intake manifold bolt and grommet assembly (part of 9424) (8 required) |
| 30 | 9424 | Intake manifold |
| 31 | W704310 | Heated PCV fitting bolt (2 required) |
| 32 | 9A474 | Heated PCV fitting |
| 33 | 9461 | Intake manifold gasket (6 required) |
ITEM DESCRIPTION
SPECIAL TOOL REFERENCE Remover, Spark Plug Wire 303-106 (T74P-6666-A)
Scheme 369
SPECIAL TOOL REFERENCE Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Vibration Damper 303-101 (T74P-3616-A) Remover, Crankshaft Vibration Damper 303-773 Strap Wrench 303-D055 (D85L-6000-A) or equivalent
Scheme 370
SPECIAL TOOL REFERENCE Aligner, Front Cover 303-093 (T74P-6019-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
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SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-A) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Remover, Spark Plug Wire 303-106 (T74P-6666-A) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A) Torque Wrench Extension 303-575 (T97T-6256-F)
SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-A) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256) Holding Tool, Crankshaft 303-674
Scheme 373
| Item | Part Number | Description |
|---|---|---|
| 1 | 6K254 | Hydraulic chain tensioner |
| 2 | 6M276 | Camshaft sprocket bolt |
| 3 | 6M276 | Jackshaft sprocket bolt |
| 4 | W500011 | Jackshaft chain tensioner bolts (2 required) |
| 5 | 6M271 | Jackshaft chain tensioner |
| 6 | Jackshaft chain and sprocket assembly | |
| 7 | 6U001 | LH cassette upper bolt |
| 8 | W500110 | LH cassette lower bolt |
| 9 | 6M289 | LH cassette |
ITEM DESCRIPTION
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- Remove the valve covers. For additional information, refer to «VALVE COVER - RH»(ref-365365-S20321358132010070700000) and «VALVE COVER - LH»(ref-365365-S29060672082010070700000) .
- Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.0L SOHC»(ref-365424) .
- Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365365-S42857481252010070700000) .
- Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-365412) .
- Remove all of the roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-365365-S01832068132010070700000) .
- NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
- Remove the LH hydraulic chain tensioner. Discard the washer.
- Remove the LH camshaft sprocket bolt. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 and tighten the bolts to 10 Nm (89 lb-in). Remove the LH camshaft sprocket bolt.
- Using the Crankshaft Holding Tool to prevent the crankshaft from turning, remove the jackshaft sprocket bolt.
- Remove the 2 bolts and the primary chain tensioner.
- Remove the primary chain and sprockets as an assembly.
- Remove the LH cassette upper bolt.
- Remove the LH cassette lower bolt and the LH cassette.
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- NOTE: The camshaft chain sprockets must be oriented correctly. Position the LH cassette.
- Install the LH cassette lower bolt. Tighten to 19 Nm (168 lb-in).
- Install the LH cassette upper bolt. Tighten to 12 Nm (106 lb-in).
- Install the jackshaft chain and sprockets as an assembly.
- Install the jackshaft chain tensioner and the bolts. Tighten to 9 Nm (80 lb-in).
- Using the Crankshaft Holding Tool to prevent the crankshaft from turning, tighten the jackshaft sprocket bolt in 2 stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten an additional 90 degrees.
- Loosely install the camshaft sprocket bolt.
- Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-365365-S42857481252010070700000) .
- NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed. NOTE: Install the LH hydraulic chain tensioner during camshaft timing. Time the LH and RH camshafts. For additional information, refer to «CAMSHAFT TIMING»(ref-365365-S23613813062010070700000) .
- Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-365365-S01832068132010070700000) .
- Install the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-365412) .
- Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.0L SOHC»(ref-365424) .
- Install the valve covers. For additional information, refer to «VALVE COVER - RH»(ref-365365-S20321358132010070700000) and «VALVE COVER - LH»(ref-365365-S29060672082010070700000) .
- Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-365412) .
SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-A) Extension, Torque Wrench 303-575 (T97T-6256-F) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G)
SPECIAL TOOL REFERENCE Compressor, Valve Spring 303-581 (T97T-6565-A)
Scheme 380
SPECIAL TOOL REFERENCE Compressor, Valve Spring 303-581 (T97T-6565-A)
SPECIAL TOOL REFERENCE Installer, Valve Stem Seal 303-370 (T90T-6571-A)
SPECIAL TOOL REFERENCE Adapter for 303-290A 303-290-01 Adapter for 303-290A 303-290A-03A Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-290A
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SPECIAL TOOL REFERENCE Adapter for 303-579 303-527 (T95T-6701-A3) Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Screws, Crankshaft Rear Oil Seal 303-528 (T95T-6701-A4)
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SPECIAL TOOL REFERENCE Adapter for 303-290A 303-290-01 Adapter for 303-290A 303-290A-03A Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-290A
SPECIAL TOOL REFERENCE Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Spark Plug Wire Remover 303-106 (T74P-6666-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
Scheme 385
SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-C) Compressor, Valve Spring 303-581 (T97T-6565-A) Heavy Duty Floor Crane 014-00071 or equivalent Holding Tool, Camshaft 303-564 (T97T-6256-B) Lifting Bracket, Engine 303-050 (T70P-6000) Rear Jackshaft Socket 303-634 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-101 (T74P-6316-A) Remover, Crankshaft Vibration Damper 303-773 Remover, Oil Seal 303-409 (T92C-6700-CH) Spreader Bar 303-106 (T74P-6666-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent
SPECIAL TOOL REFERENCE Compressor, Valve Spring 303-581 (T97T-6565-A) Installer, Valve Stem Oil Seal 303-370 (T90T-6571-A)
SPECIAL TOOL REFERENCE Service Set, Piston Pin 303-S024 (T68P-6135-A)
SPECIAL TOOL REFERENCE Adapter for 303-564 303-578 (T97T-6256-A) Adapter for 303-577 303-576 (T97T-6256-D) Adapter for 303-579 303-527 (T95T-6701-A3 Aligner, Front Cover 303-093 (T74P-6019-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Compressor, Valve Spring 303-581 (T97T-6565-A) Heavy Duty Floor Crane 014-00071 or equivalent Holding Tool, Camshaft 303-577 (T97T-6256-C) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Lifting Brackets, Engine 303-050 (T70P-6000) Screws, Crankshaft Rear Oil Seal 303-528 (T95T-6701-A4) Socket, Rear Jackshaft 303-634 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (85L-6000-A) or equivalent Tensioner, Timing Chain 303-571 (T97T-6K254-A) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
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SPECIAL TOOL REFERENCE Heavy Duty Lifting Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent