Service Procedure
Caution:Before servicing any electrical component, the ignition key must be in the Off or LOCK position and all electrical loads must be Off, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
1. Record vehicle preset radio stations.
2. Turn OFF all the lamps and the accessories.
3. Make sure the ignition switch is in the OFF position.
4. Disconnect negative battery cable (2).
Caution:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
Caution:
To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack.
Notice:
Perform the following steps before beginning any vehicle lifting or jacking procedure:
^ Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.
^ The lifting or jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.
^ The lifting or jacking equipment must meet the operational standards of the lifting or jacking equipment's manufacturer.
^ Perform vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
^ Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting or jacking equipment, the vehicle, and/or the vehicle's contents.
Important:
Place jackstands ONLY under strong and stable vehicle structures.
5. Raise vehicle on hoist until the tires are off the ground. Place front lift pads (1 in illustration) 170 mm (6.69 in) from front pinchweld flanges, rear lift pads (2) 55 mm (2.17 in) from rear pinchweld flanges.
6. Remove right front tire.
7. Remove inner right side splash shield to gain access to crankshaft pulley.
8. Remove ignition coil/spark plug cover.
9. Remove cylinder # 4 ignition coil and spark plug.
10. Install spark plug adapter 309729 from SA9127E Universal Pressure Test Kit in # 4 cylinder spark plug hole.
11. Hang gauge bar 53476 from "D-Ring" on the hood and align the gauge so that you can see it from the right front tire area of the vehicle. Attach pressure hose 309734 to the "Pressure Oil, Fuel, Cylinder Leak" port of the gauge bar and spark plug adapter.
Important:
To determine # 4 cylinder top dead center (TDC) compression stroke, rotate the engine by the crankshaft pulley and watch the pressure gauge on the gauge bar. When pressure begins to build use an inspection mirror and continue to rotate the crankshaft pulley until the timing marks are aligned as shown in the illustration.
12. Rotate the engine to bring the cylinder # 4 to top dead center (TDC) compression stroke. The crankshaft pulley-timing notch should be aligned with the timing mark on the front cover.
13. Remove powertrain control module (PCM) from mounting bracket. Do NOT disconnect any electrical connectors. Use the retaining tab to release the PCM from the underhood junction block bracket.
14. Perform underhood electrical center removal procedure.
A. Remove the cover from the underhood electrical center.
B. Remove the underhood positive battery terminal lug (1).
Important:
Take note of the positioning of the positive battery cables before disconnecting the cables.
C. Disconnect the positive battery cables (2) from the underhood electrical center.
D. Remove the electric power steering (EPS) cable nut from the underhood electrical center.
E. Disconnect the EPS cable (3) from the underhood electrical center.
F. Release the engine wiring harness retainer (1), next to the powertrain control module (PCM). Reposition the wiring harness (2) toward the engine.
G. Release the EPS cable retainer from the underhood electrical center bracket.
H. Release the forward lamp harness retainer from the outboard side of the PCM tray.
I. Release the surge tank inlet hose clip from the electrical center bracket.
I. Remove the cooling system surge tank mounting nut.
K. Remove the underhood electrical center bracket mounting nut.
L. Remove the electrical center bracket mounting bolt.
M. Lift the bracket off of the studs and reposition the bracket slightly toward the engine.
N. Lift the surge tank hose (1) slightly and move the electrical center and electrical center bracket (2) toward the front of the vehicle.
15. Remove the two fasteners holding the clutch master cylinder to the front of dash to allow easier access to the camshaft position sensor housing.
16. Remove the brake booster vacuum hose from the supercharger and set it aside.
17. Remove the two fasteners (studs) holding the camshaft position sensor housing assembly to the cylinder head.
18. Slide the camshaft position sensor housing assembly back away from the cylinder head.
19. Remove and discard green camshaft position sensor housing seal.
20. Using a shop towel, wipe clean the "cog" (hex shaft) of the camshaft position trigger and the mating surfaces of the camshaft position sensor housing assembly and the cylinder head.
21. Place two 6 mm (0.236 in) - 10 mm (0.393 in) dots of ThreeBond 1217F(R) sealant, P/N 12378521, on the cylinder head as shown in illustration.
22. Install the NEW camshaft position sensor housing seal, P/N 12597644. The new seal is black.
23. Align the timing mark on the "cog" (hex shaft) to the timing mark on the camshaft position sensor housing.
24. Install the camshaft position sensor housing assembly to the cylinder head.
Notice:
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
25. Install the camshaft position sensor housing studs.
Tighten
Tighten the camshaft position sensor housing studs to 22 Nm (16 lb-ft).
26. Install brake booster vacuum hose to supercharger.
27. Install the two fasteners to the clutch master cylinder.
Tighten
Tighten fasteners to 10 Nm (89 lb-in).
28. Perform underhood electrical center installation procedure.
^ Position the electrical center bracket (2) to the vehicle.
A. Lift the surge tank inlet hose (1) slightly and move the electrical center bracket (2) toward the rear of the vehicle, just inboard of the installed position.
B. Position the electrical center bracket onto the studs at the surge tank and on the frame rail.
C. Install the underhood electrical center bracket mounting bolt. Do not tighten yet.
D. Install the underhood electrical center bracket mounting nut.
Tighten
Tighten the bracket mounting nut to 10 Nm (89 lb-in).
E. Install the cooling system surge tank mounting nut.
Tighten
Tighten the surge tank mounting nut to 10 Nm (89 lb-in).
F. Tighten the underhood electrical center bracket mounting bolt.
Tighten
Tighten bracket mounting bolt to 25 Nm (18 lb-ft).
G. Secure the forward lamp harness retainer to the outboard side of the PCM tray.
H. Secure the EPS cable retainer to the underhood electrical center bracket.
I. Install the engine wiring harness (2) to the retainer (1), next to the PCM. Secure the harness retainer (1).
J. Connect the EPS cable (3) to the underhood electrical center.
K. Install the electric power steering (EPS) cable nut.
Tighten
Tighten the EPS cable nut to 10 Nm (89 lb-in).
L. Connect the positive battery cables (2) to the underhood electrical center. Position the cables as noted previously.
M. Install the underhood positive battery terminal lug (1).
Tighten
Tighten the battery lug to 15 Nm (11 lb-ft).
N. Install the cover to the underhood electrical center.
29. Install PCM. Secure PCM to underhood junction block bracket with retaining tab.
30. Install the right front inner splash shield.
31. Install the right front tire. Tighten nuts in a "star" pattern.
Tighten
Tighten wheel nuts 140 Nm (100 lb-ft)
32. Lower vehicle.
Important:
Make sure that the ignition coil seals are properly seated to the valve cover.
33. Remove spark plug adapter, house and gauge bar.
34. Install cylinder # 4 ignition coil and spark plug.
Tighten
Tighten spark plug to 20 Nm (15 lb-ft). Tighten ignition coil retaining bolts to 10 Nm (89 lb-in).
35. Install ignition coil/spark plug cover retaining bolts.
Tighten
Tighten ignition coil/spark plug cover retaining bolts to 8 Nm (71 lb-in).
36. Connect the battery negative cable to the battery (2).
Tighten
Tighten cable bolt to 17 Nm (13 lb-ft).
37. Reset the radio stations and the clock.
38. Check oil level and adjust if necessary.
Important:
If engine exhibits an extended crank of over 3 seconds, the cam shaft position sensor housing may not be timed properly. Verify the position of the camshaft sensor housing and adjust if necessary using the procedures outlined in this bulletin. Start engine to verify there are no leaks and the camshaft position sensor housing is timed properly.