Valve Lifter Replacement - Right Side (L84)

Single Use Fasteners and Components Cylinder Head Bolt [10x] Cylinder Head Gasket Exhaust Manifold Bolt [5x] Exhaust Manifold Gasket Exhaust System Seal Fuel Feed Intermediate Pipe [2x] Intake Manifold Gasket [8x] Oil Filter Valve Rocker Arm Cover Gasket Special Tools EN-47909 Injector Bore and Sleeve Cleaning Kit J-8089 Carbon Removal Brush J-9666 Valve Spring Tester Equivalent regional tools: Special Tools

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning.

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury. Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief

Valve Lifter Replacement - Right Side (L84) — figure 1

2. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
3. Drain the cooling system. Cooling System Draining and Filling
4. Engine Oil and Oil Filter » Remove and DISCARD — Engine Oil and Oil Filter Replacement
5. Front Wheelhouse Liner - Right Side » Remove — Front Wheelhouse Liner Replacement

Valve Lifter Replacement - Right Side (L84) — figure 2

Note

Some components not shown for graphic clarity. Pull only on the spark plug wire boot to remove the wire.

6. Twist the 4 spark plug wire boots a ½ turn and remove the 4 spark plug wires (1) from the 4 gas engine ignition spark plugs (2).

Valve Lifter Replacement - Right Side (L84) — figure 3

7. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Remove [3x]

Valve Lifter Replacement - Right Side (L84) — figure 4

8. Remove the right exhaust manifold heat shield (1) through the wheel opening.

Valve Lifter Replacement - Right Side (L84) — figure 5

9. Exhaust Heat Shield Bolt - Right Side (1) » Remove
10. Exhaust Front Pipe Heat Shield - Right Side (2) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 6

11. Retainer Clip (1) @ Cylinder Head - Right Side (2) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 7

12. Disconnect the heated oxygen sensor electrical connector.

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution.

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

13. Using a suitable tool, remove the heated oxygen sensor (1).

Valve Lifter Replacement - Right Side (L84) — figure 8

14. Exhaust Front Pipe Nut - Right Side (1) » Remove [3x]

Valve Lifter Replacement - Right Side (L84) — figure 9

15. Exhaust Manifold Bolt - Right Side (1) » Remove and DISCARD [5x]

Valve Lifter Replacement - Right Side (L84) — figure 10

16. Exhaust Manifold - Right Side (1) » Remove
17. Exhaust Manifold Gasket - Right Side (2) » Remove and DISCARD

Valve Lifter Replacement - Right Side (L84) — figure 11

18. Exhaust System Seal - Right Side (1) » Remove and DISCARD
19. Lower the vehicle.

Valve Lifter Replacement - Right Side (L84) — figure 12

20. Positive Crankcase Ventilation Tube Connector (2) @ Air Cleaner Outlet Duct » Disconnect — Plastic Collar Quick Connect Fitting Service
21. Positive Crankcase Ventilation Tube Connector (3) @ Positive Crankcase Ventilation Fitting » Disconnect — Plastic Collar Quick Connect Fitting Service
22. Positive Crankcase Ventilation Fresh Air Tube (1) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 13

23. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
24. Disconnect the electrical connector and retainers as needed.

Valve Lifter Replacement - Right Side (L84) — figure 14

25. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
26. Air Cleaner Outlet Duct (3) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 15

27. Oil Level Indicator Tube Bolt (1) @ Cylinder Head - Right Side » Remove

Valve Lifter Replacement - Right Side (L84) — figure 16

28. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Disengage — Plastic Collar Quick Connect Fitting Service
29. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Remove and position aside

Valve Lifter Replacement - Right Side (L84) — figure 17

30. Engine Wiring Harness Connector (1) @ Throttle Body » Disconnect
31. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Remove [2x]
32. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Disconnect
33. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Disconnect

Valve Lifter Replacement - Right Side (L84) — figure 18

34. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Valve Lifter Replacement - Right Side (L84) — figure 19

35. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Valve Lifter Replacement - Right Side (L84) — figure 20

36. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Valve Lifter Replacement - Right Side (L84) — figure 21

Note

Some components not shown for graphic clarity.

37. Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
38. Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.

Valve Lifter Replacement - Right Side (L84) — figure 22

39. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Valve Lifter Replacement - Right Side (L84) — figure 23

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

40. Remove the intake manifold and intake manifold cover (1) as an assembly.
41. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.

Valve Lifter Replacement - Right Side (L84) — figure 24

42. Intake Manifold Gasket (1) » Remove and DISCARD [8x]

Valve Lifter Replacement - Right Side (L84) — figure 25

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 43. Fuel Pump Insulator (1) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 26

Caution

Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.

Note

Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

44. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) » Loosen until disengaged [2x]
45. Fuel Feed Intermediate Pipe (2) » Remove and DISCARD
46. Disconnect the electrical wiring harness connectors from the fuel rails as needed.

Valve Lifter Replacement - Right Side (L84) — figure 27

Note

Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

47. Fuel Feed Intermediate Pipe Nut (1) » Loosen until disengaged [2x]
48. Fuel Feed Pipe Bolt (2) » Remove
49. Fuel Feed Intermediate Pipe (3) » Remove and DISCARD

Valve Lifter Replacement - Right Side (L84) — figure 28

50. Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (1) from the 3 valve rocker arm cover insulator retainers (2).
51. Valve Rocker Arm Cover Insulator (3) » Remove
52. Inspect the 3 upper intake manifold sight shield grommets (1) on the valve rocker arm cover insulator (3) and replace as necessary.

Valve Lifter Replacement - Right Side (L84) — figure 29

53. Heater Hose Clip Bracket Bolt (1) » Remove
54. Heater Inlet and Outlet Hose Bracket (2) » Reposition
55. Engine Wiring Harness Connector @ Ignition Coil » Disconnect [4x]

Valve Lifter Replacement - Right Side (L84) — figure 30

56. Valve Rocker Arm Cover Bolt (1) » Loosen until disengaged [10x]
57. Valve Rocker Arm Cover - Right Side (2) » Remove

Valve Lifter Replacement - Right Side (L84) — figure 31

58. Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) » Remove and DISCARD

Valve Lifter Replacement - Right Side (L84) — figure 32

Note

Only replace the valve rocker arms and valve push rods as required. The rocker arm pivot support bolts are not serviced separately. Place the valve rocker arms and valve push rods in a rack so they can be installed in the same location from which they were removed.

59. Valve Rocker Arm Pivot Support Bolt (1) » Loosen until disengaged [8x]
60. Valve Rocker Arm (2) » Remove [8x]

Valve Lifter Replacement - Right Side (L84) — figure 33

61. Valve Push Rod (1) » Remove [8x]

Valve Lifter Replacement - Right Side (L84) — figure 34

Note

Some components not shown for graphic clarity.

62. Engine Wiring Harness Ground Bolt (1) » Remove
63. Engine Wiring Harness (2) @ Cylinder Head » Disconnect

Valve Lifter Replacement - Right Side (L84) — figure 35

64. Generator Bolt (1) » Loosen until disengaged

Valve Lifter Replacement - Right Side (L84) — figure 36

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

65. Cylinder Head Bolt (1) » Remove and DISCARD [10x]

Valve Lifter Replacement - Right Side (L84) — figure 37

Caution

After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

66. Cylinder Head (1) » Remove
67. Cylinder Head Gasket (2) » Remove and DISCARD

Valve Lifter Replacement - Right Side (L84) — figure 38

Note

Organize and mark the valve lifters (1), valve lifter guides (2), and valve lifter guide bolts (3) so they can be installed to their original location. The valve lifter guide bolt must match the valve lifter guide it came with. If the valve lifter guide bolt requires replacement, replace the valve lifter guide as well. Only replace the valve lifters (1), valve lifter guides (2), and valve lifter guide bolts  (3) as required.

68. Valve Lifter Guide Bolt (3) » Loosen until disengaged

Note

Note the installed position of the valve lifter guides (2). The notched area of the valve lifter guides (2) align with the locating tab on the engine block.

69. Remove the valve lifter guide (2) and the valve lifters (1) as an assembly.

Valve Lifter Replacement - Right Side (L84) — figure 39

70. Valve Lifter (1) @ Valve Lifter Guide (2) » Remove
71. Using the appropriate tool, clean and prepare the applicable sealing surface. Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Valve Lifter Replacement - Right Side (L84) — figure 40

Note

When cleaning a cylinder head in a thermal type oven, do not exceed 204°C (400°F). Be careful not to scuff the chamber.

1. Clean the following components: 1.1. Use the J-8089 Carbon Removal Brush (1) in order to remove the carbon from the combustion chambers. 1.2. Gasket surfaces 1.3. Valve stems and heads on a buffing wheel 1.4. Bolt hole threads 1.5. Remove all dirt, debris, or threadlocking material from the bolt holes.

Valve Lifter Replacement - Right Side (L84) — figure 41

2. Inspect the fuel rail injector bores and clean with EN-47909 Injector Bore and Sleeve Cleaning Kit (1), if required.
3. Inspect the cylinder head for the following conditions: 3.1. Cracks in the exhaust ports and combustion chambers 3.2. External cracks in the water chambers 3.3. Gasket surfaces for excessive scratches or gouging 3.4. Bolt hole threads for debris or damaged threads Thread Repair Thread Repair Specifications

Valve Lifter Replacement - Right Side (L84) — figure 42

4. Inspect the cylinder head for warpage. Engine Mechanical Specifications

Valve Lifter Replacement - Right Side (L84) — figure 43

5. Using the J-9666 Valve Spring Tester (1), measure the valve spring tension. Engine Mechanical Specifications.

Valve Lifter Replacement - Right Side (L84) — figure 44

6. Clean all sealing surfaces.
7. Dry the intake manifold with compressed air.
8. Inspect the intake manifold cylinder head deck for warpage.
9. Place a straight edge (1) across the intake manifold cylinder head deck surface.
10. Inspect the intake manifold for the following conditions: 10.1. Inspect for loose threaded inserts or studs. 10.2. Inspect for damaged or broken vacuum fitting. 10.3. Inspect the intake manifold assembly for cracks or other damage. 10.4. Inspect for damaged intake manifold gasket sealing surfaces.
11. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications
12. Inspect the ventilation system passages for restrictions.

Valve Lifter Replacement - Right Side (L84) — figure 45

13. Clean the exhaust manifold (1) and heat shield (2) in solvent.
14. Dry the exhaust manifold (1) with compressed air.
15. Inspect the exhaust manifold (1) to the cylinder head exhaust manifold gasket surface for excessive scratches or gouging.
16. Inspect for a loose, damaged, or cracked heat shield (2).
17. Inspect the heat shield bolts (3) for damaged threads.

Valve Lifter Replacement - Right Side (L84) — figure 46

18. Use a straight edge (1) and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold cylinder head deck with warpage in excess of 0.25 mm (0.01 in) within the 2 front or 2 rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak. Exhaust manifolds not within specifications MUST be replaced.

Valve Lifter Replacement - Right Side (L84) — figure 47

19. Remove the 8 ignition coil bolts (1) and 4 ignition coils (2) before cleaning the valve rocker arm cover (3) in solvent. Do NOT submerge the 4 ignition coils (2) in solvent.
20. Inspect the valve rocker arm cover (3) for the following conditions: 20.1. Scoring or damage to the gasket surfaces 20.2. Ventilation system passages for restrictions 20.3. Threaded bolt holes for damage or debris
21. Install the 4 ignition coils (2).

Caution

Refer to Fastener Caution.

22. Install and tighten the 8 ignition coil bolts (1). Fastener Specifications

Valve Lifter Replacement - Right Side (L84) — figure 48

Note

Components that are to be used again must be marked, sorted or organized for assembly.

23. Clean the components in cleaning solvent.

Warning

Refer to Safety Glasses and Compressed Air Warning.

24. Dry the components with compressed air.
25. Inspect the valve lifters for the following conditions: 25.1. Broken or collapsed spring (1) 25.2. Worn pushrod socket (2) 25.3. Plugged lubrication hole (3) 25.4. Plugged lifter oil switching hole (4) 25.5. Flat spots on the roller (5) 25.6. Worn or damaged roller bearing (6) The roller should rotate freely with no binding or roughness. 25.7. Scuffed or worn sides (7)

Valve Lifter Replacement - Right Side (L84) — figure 49

26. Inspect the valve lifter guides for the following conditions:
27. Cracks or damage (1)
28. Excessive wear in the lifter mounting bores (2)

Valve Lifter Replacement - Right Side (L84) — figure 50

Note

Parts that are to be used again must be marked, sorted or organized for assembly.

29. Mark, sort, or organize the components for assembly.
30. Clean the components with cleaning solvent.

Warning

Refer to Safety Glasses and Compressed Air Warning.

31. Dry the components with compressed air.
32. Inspect the valve rocker arms bearings (2) for binding or roughness.
33. Inspect the valve rocker arm pushrod sockets (3) and valve stem mating surfaces (1). These surfaces should be smooth with no scoring or exceptional wear.
34. Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
35. Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
36. Inspect the pushrod oil passages for restrictions.
37. Inspect the rocker arm pivot supports for cracks, wear, or other damage.

Note

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.

38. Inspection the spark plug wire for the following conditions: 38.1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 38.2. Inspect for any signs of cracks or splits in the wires.
39. Inspect each boot for the following conditions: 39.1. Tearing 39.2. Piercing 39.3. Arcing 39.4. Carbon tracking 39.5. Corroded terminals
40. If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Installation Procedure

Note

When reusing valve lifters (1), install the lifters to their original locations. Only replace the valve lifters (1) and valve lifter guides (2) as required. If camshaft replacement is required, the valve lifters (1) must also be replaced

1. Lubricate the valve lifters (1), valve lifter guides (2) and the engine block valve lifter bores with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
2. Install the raised surface of the valve lifter (1) into the notched area of the valve lifter guide (2).

Note

The notched area of the valve lifter guides (2) align with the locating tab on the engine block.

3. Install the valve lifter guide (2) and the valve lifters (1) as an assembly.

Caution

Refer to Fastener Caution.

4. Valve Lifter Guide Bolt (3) » Install and tighten — Fastener Specifications

Note

Ensure the proper orientation of the gasket using the marks provided on the gasket. Gaskets are stamped with orientation marks. Make sure “FRONT” is visible on the top of the gasket and toward the front of the engine.

5. Cylinder Head Gasket (2) » Install NEW
6. Cylinder Head (1) » Install

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

7. Cylinder Head Bolt (1) » Install NEW and hand tighten [10x]
8. Cylinder Head Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

Note

Some components not shown for graphic clarity.

9. Generator Bolt (1) » Install and tighten — Fastener Specifications

10. Oil Level Indicator Tube Bolt (1) @ Cylinder Head - Right Side » Install and tighten — Fastener Specifications

11. Engine Wiring Harness (2) @ Cylinder Head » Connect

12. Engine Wiring Harness Ground Bolt (1) » Install and tighten — Ground Repair

13. Lubricate the flange of the 8 valve rocker arm bolts with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

14. Lubricate the 8 valve rocker arms and push rods with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

Note

Valve lash is net build. No valve adjustment is required. Ensure the push rods seat properly to the valve lifter sockets.

15. Valve Push Rod (1) » Install [8x]

Note

The rocker arm bolts are not serviced separately.

16. Valve Rocker Arm (2) » Install [8x]

17. Valve Rocker Arm Pivot Support Bolt (1) » Hand tighten [8x]

18. Valve Rocker Arm Pivot Support Bolt (1) » Tighten [8x] — Fastener Specifications

19. Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) » Install NEW

Note

Some components not shown for graphic clarity.

20. Valve Rocker Arm Cover - Right Side (2) » Install

21. Valve Rocker Arm Cover Bolt (1) » Hand tighten [10x]

22. Valve Rocker Arm Cover Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

23. Engine Wiring Harness Connector @ Ignition Coil » Connect [4x]

24. Heater Inlet and Outlet Hose Bracket (2) » Reposition

25. Heater Hose Clip Bracket Bolt (1) » Install and tighten — Fastener Specifications

26. Valve Rocker Arm Cover Insulator (3) » Install

27. Install the 3 upper intake manifold sight shield grommets (2) to the 3 valve rocker arm cover insulator retainers (1).

Valve Lifter Replacement - Right Side (L84) — figure 51

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (3) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

28. Fuel Feed Intermediate Pipe (1) » Install NEW 28.1. Slide the 2 fuel feed intermediate pipe nuts (3) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (2) of the fuel feed intermediate pipe (1). 28.2. Carefully install the 2 formed ends (2) of the fuel feed intermediate pipe (1) into the sockets of the left and right fuel injection fuel rail. Take care not to hit the 2 formed ends  (2) of the fuel feed intermediate pipe (1) on the threaded sockets on the fuel injection fuel rails. 28.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (3).
29. Fuel Feed Pipe Bolt (4) » Tighten — Fastener Specifications
30. Fuel Feed Intermediate Pipe Nut (3) » Tighten [2x] — Fastener Specifications

Valve Lifter Replacement - Right Side (L84) — figure 52

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (2) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

31. Fuel Feed Intermediate Pipe (1) » Install NEW 31.1. Slide the 2 fuel feed intermediate pipe nuts (2) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (3) of the fuel feed intermediate pipe (1). 31.2. Carefully install the 2 formed ends (3) of the fuel feed intermediate pipe (1) into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5). Take care not to hit the 2 formed ends (3) of the fuel feed intermediate pipe (1) on the threaded sockets of the fuel pump (4) and fuel feed intermediate pipe (5). 31.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (2).
32. Fuel Feed Intermediate Pipe Nut (2) » Tighten [2x] — Fastener Specifications
33. Connect the electrical wiring harness connectors from the fuel rails.

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 34. Fuel Pump Insulator (1) » Install 35. Remove the covers from the cylinder head passages.

36. Intake Manifold Gasket (1) » Install NEW [8x]

37. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 37.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 37.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 37.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 37.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

38. Position the intake manifold and Intake manifold cover (1) to install harness retainers.

39. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

40. Move the intake manifold and intake manifold cover (2) into place.

Note

Some components not shown for graphic clarity.

41. Intake Manifold Bolt (1) » Hand tighten [10x]

42. Intake Manifold Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

43. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

44. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

45. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

46. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Connect

47. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Connect

48. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Install [2x]

49. Engine Wiring Harness Connector (1) @ Throttle Body » Connect

50. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Install

51. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Engage — Plastic Collar Quick Connect Fitting Service

52. Air Cleaner Outlet Duct (3) » Install

53. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

54. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

55. Install engine wiring harness to air cleaner outlet duct bracket.

56. Positive Crankcase Ventilation Fresh Air Tube (1) » Install

57. Positive Crankcase Ventilation Tube Connector (3) @ Positive Crankcase Ventilation Fitting » Connect — Plastic Collar Quick Connect Fitting Service

58. Positive Crankcase Ventilation Tube Connector (2) @ Air Cleaner Outlet Duct » Connect — Plastic Collar Quick Connect Fitting Service

59. Raise the vehicle.

60. Exhaust System Seal - Right Side (1) » Install NEW

61. Exhaust Manifold Gasket - Right Side (2) » Install NEW

62. Install the right side exhaust manifold (1) through the wheel opening.

63. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 63.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 63.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 63.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 63.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

64. Exhaust Manifold Bolt - Right Side (1) » Install and hand tighten [5x]

65. Exhaust Manifold Bolt - Right Side (1) » Tighten in sequence [5x] — Fastener Specifications

66. Exhaust Front Pipe Nut - Right Side (1) » Install and hand tighten [3x]

67. Exhaust Front Pipe Nut - Right Side (1) » Tighten [3x] — Fastener Specifications

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

68. Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications

69. Connect the heated oxygen sensor electrical connector.

70. Retainer Clip (1) @ Cylinder Head - Right Side (2) » Install

71. Exhaust Front Pipe Heat Shield (2) » Install

72. Exhaust Heat Shield Bolt (1) » Install and tighten — Fastener Specifications

73. Install the right exhaust manifold heat shield (1) through the wheel opening.

74. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Install and hand tighten [3x]

75. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Tighten [3x] — Fastener Specifications

76. Inspect the inside of the spark plug rubber boots for a thin, even coat of grease. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease evenly to the inside of the spark plug rubber boots up to a depth of 15 mm (0.6 in) from the end of the boot. Adhesives, Fluids, Lubricants, and Sealers

77. Push the 4 boots of the spark plug wires (1) onto the 4 gas engine ignition spark plugs (2) until 2 audible clicks are heard.

78. Install the wiring harness.

79. Front Wheelhouse Liner - Right Side (3) » Install Front Wheelhouse Liner Replacement

80. Engine Oil and Oil Filter » Install NEW — Engine Oil and Oil Filter Replacement

81. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

82. Fill the cooling system to the proper level. Cooling System Draining and Filling

83. Start the engine and check for leaks.