Installation
- Clean valve cover gasket and gasket groove in valve cover. Replace gasket if damaged. Inspect valve cover center nut washers and replace as necessary. Seat gasket into camshaft recesses first, then work gasket into groove around outside edges. Ensure valve cover gasket is seated into corners of recesses, with no gap. Ensure mating surfaces are clean and dry.
- Apply liquid gasket to 8 corners of camshaft recesses of valve cover gasket. Hold gasket in groove by positioning fingers on camshaft holder contacting surfaces (top of semicircles). After valve cover is positioned onto cylinder head, slide cover back and forth slightly to seat gasket.
- Valve cover must be installed within 5 minutes of liquid gasket application. If more than 5 minutes has passed, remove old liquid gasket and reapply. Tighten nuts to specification in 2-3 steps. Start with center nut in middle row, both ends of middle row and then alternately tighten 4 remaining side nuts. See «TORQUE SPECIFICATIONS»(ref-8296-S28879535012000082200000) . To complete installation, reverse removal procedure. Wait at least 20 minutes before filling engine with oil.
Removal
- Open hood as far as possible, and secure. Disconnect negative battery cable, and then positive battery cable. Disconnect battery cables from underhood fuse/relay box. Disconnect positive battery cable. Remove battery and battery base. Remove intake air duct and air cleaner housing.
- Disconnect Powertrain Control Module (PCM) connectors and main wiring harness connector. Remove grommet and wiring harness clamps, and pull PCM connectors through firewall. Disconnect engine wiring harness connectors on left side of engine compartment.
- Remove cruise control actuator with cable attached, and move aside. Without disconnecting hoses, remove power steering pump, and position aside. Remove A/C compressor drive belt. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8296-S31867253542000082200000). Remove EVAP control canister hose from canister and fuel feed hose from fuel filter. Remove brake booster vacuum hose, fuel return hose, and vacuum hose from intake manifold.
- Remove throttle cable by loosening lock nut, and slipping cable ends out of throttle linkage. It is not necessary to loosen adjusting nut. Disconnect generator connector and terminal. Disconnect Power Steering Pressure (PSP) switch connector, and remove harness clamp. NOTE: DO NOT bend throttle cable when removing. DO NOT use pliers to remove cable from linkage. Replace cable if kinked or damaged. Adjust cables when reinstalling.
- On M/T models, remove clutch slave cylinder and fluid line bracket. Remove ground cable from transmission. Remove shift control cables and bracket from transmission. On all models, set heater controls to maximum heat, and remove radiator cap. Raise and support vehicle. Remove front wheels and guard bar/splash shield. Loosen radiator drain plug, drain coolant and retighten drain plug.
- Remove engine block coolant drain plug, located next to exhaust manifold, and drain engine block coolant. see scheme 4 Drain engine oil and transmission fluid. After draining fluids, reinstall all drain plugs with NEW washers, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-8296-S28879535012000082200000). Without disconnecting hoses, remove A/C compressor, and position aside.
- Disconnect primary HO2S-1 connector, and remove front exhaust pipe. Discard exhaust pipe nuts and gaskets. On A/T models, remove shift cable cover and remove shift cable. DO NOT bend shift control cable when removing. Always replace kinked or damaged cable. On all models, remove front axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Remove drive shaft. See 4WD DIFFERENTIAL & AXLE SHAFTS article in DRIVE AXLES. Lower vehicle.
- Remove upper and lower radiator hoses. Remove heater hoses. On A/T models, disconnect transmission ground cable and hose clamp. Remove ATF cooler hoses, and plug hose openings. On all models, disconnect fan motor connectors. Remove radiator upper brackets and fan shroud. Remove radiator assembly. Remove A/C hose clamp.
- Attach chain hoist to engine and remove slack. Remove left and right front engine mounts and brackets. Remove rear engine mount bracket 12-mm through-bolt, and discard bolt. (Scheme 2)
- Remove side engine mount upper bracket. Remove transmission mount bracket and transmission mount. Ensure engine/transmission assembly is free of all attachments. Slowly lift engine about 6", and again ensure engine/transmission assembly is free of all attachments. Lift engine/transmission assembly from vehicle.
Scheme 2
Note. Tighten engine/transmission mounting nuts and bolts to specification in sequence. See TORQUE SPECIFICATIONS. Improper tightening of engine mounts will result in excessive engine noise and vibration, and premature mount wear. Some engine/transmission mount bolts and nuts are not reusable. (Scheme 2)
- Install transmission mount and bracket, and tighten 12-mm frame side bolts. Install, but do not tighten, transmission side nuts and through-bolt. Install side engine mount upper bracket. Tighten one 12-mm mount (frame side) nut first, and then two 12-mm mount (engine side) nuts. (Scheme 2)
- Install NEW rear mount bracket through-bolt, but do not tighten. Tighten transmission mount bracket 12-mm nuts to transmission side, and then tighten transmission mount 12-mm through-bolt. Tighten NEW rear mount-to-bracket through-bolt. (Scheme 2)
- Install right front mount/bracket. Loosen right front mount/bracket 12-mm bracket-to-mount nut. Tighten NEW 12-mm bracket bolts to engine side, and then tighten 10-mm mount bolts to frame. Install left front mount and through-bolt. Tighten 12-mm through-bolt to engine. Tighten 10-mm mount bolts to frame. Tighten NEW 12-mm through-bolt-to-mount nut. Replace right front mount/bracket 12-mm bracket-to-mount nut and tighten to specification. (Scheme 2)
- To complete installation, reverse removal procedure. Use NEW spring clips when installing axle shafts. Ensure axle shaft spring clip clicks into groove of differential side gear. Ensure all wires and hoses are connected properly. Ensure control cables are mounted properly.
- Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-8296-S42686236522000082200000). Fill engine and transmission fluids to proper level. Ensure transmission shifts smoothly, and range indicator agrees with actual transmission range.
- Adjust tension of accessory drive belts. After installation is complete, turn ignition on for 2 seconds to allow fuel system to pressurize (DO NOT start engine). Repeat procedure 2 or 3 times. Ensure no fuel system leaks exist. Check and adjust wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.