Service Procedure
VALVE SERVICE 3.3L ENGINEValves and Valve Springs
Removal
(1) Perform fuel system pressure release procedure (before attempting any repairs).
Fuel System Pressure Release Procedure The MPI fuel system is under a constant pressure of approximately 330 kPa (48 psi). Before servicing the fuel pump, fuel lines, fuel filter, throttle body or fuel injector, the fuel system pressure must be relessed.
(a) Remove fuel filler cap to release fuel tank pressure.
Figure 1 - Throttle Body Assembly 3.3L:
(b) For service access, remove air cleaner cover and hose assembly (Fig. 1).
Figure 2 - Injector Harness Connectors:
(c) Disconnect the 10-pin injector wiring harness connector from main harness.
(d) Connect a jumper wire to ground terminal Number 1 of the injector harness (Fig. 2) to engine ground.
(e) Connect a jumper wire to the positive terminal Number 2 of the injector harness (Fig. 2) and touch the battery positive post for no longer than 5 seconds. This releases system pressure.
(f) Remove jumper wire.
(2) Disconnect the second, 2-way injector wiring harness connector from main harness.
(3) Disconnect negative battery cable.
Figure 3 - Throttle Cable Attachment:
(4) Disconnect throttle and cruise control cables from throttle body and throttle cable bracket (Fig. 3). Detach wiring harness clips from throttle cable bracket and intake manifold water tube.
Figure 4 - Electrical and Vacuum Connection to Throttle Body:
(5) Disconnect automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors from throttle body (Fig. 4).
(6) Disconnect the two vacuum hose harness connections from top of throttle body (Fig. 4).
(7) Disconnect PCV and brake booster hoses from air intake plenum.
Figure 5 - Electrical and Vacuum Connections To Intake Manifold:
(8) Disconnect EGR tube flange from intake plenum (Fig. 5). (California models only)
(9) Disconnect Charge Temperature Sensor electrical connector. Remove vacuum harness connectors from Intake Plenum (Fig. 5).
(10) Remove the strut to intake manifold bolt (Fig. 5). Loosen bolt at other end (Rear of cylinder head) and move strut away from manifold.
Figure 6 - MAP Sensor Electrical Connector:
(11) Disconnect MAP Sensor and heated Oxygen Sensor electrical connection. Disconnect the engine mounted ground strap (Fig. 6).
Figure 7 - Ignition Coils:
(12) Disconnect 4-way electrical connector from direct ignition system (DIS) coil module (Fig. 7).
(13) Remove the 4 bolts which attach the DIS coil module to the intake plenum and the alternator bracket to intake plenum bolt (Fig. 7). Disconnect plug wires from spark plugs and remove DIS coil module with the wires attached.
Figure 8 - Intake Manifold Bolts:
(14) Remove intake manifold bolts, rotate plenum back over rear valve cover and remove plenum (Fig. 8).
Figure 9 - Fuel Rail Attaching Bolts:
(15) Cover lower intake manifold openings with suitable cover when servicing (Fig. 9).
(16) Disconnect vacuum harness connector from Fuel Pressure Regulator.
Figure 10 - Quick Connect Fuel Fittings to Fuel Rail:
(17) Disconnect the fuel hose quick connect fittings from the fuel rail by pushing in on the plastic rings located on the end of the fittings. Gently pull the fittings from the fuel rail (Fig. 10).
WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
(18) Disconnect cam sensor, coolant temperature sensor, and engine temperature sensors.
Figure 11 - Fuel Injector Wiring Clip:
(19) Detach fuel rail injector wiring clip from the alternator bracket (Fig. 11).
Figure 9 - Fuel Rail Attaching Bolts:
(20) Remove fuel tube retainer bracket screw and fuel rail attaching bolts (Fig. 9). Spread the retainer bracket to allow fuel tube removal clearance.
Figure 12 - Fuel Rail Removal:
(21) Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their ports (Fig. 12). Plug the injector ports to protect against contamination.
Figure 13 - Removing and Installing Valve Spring:
Replace Valve Springs, Cylinder Head Not Removed
(1) Remove valve covers and valve cover gaskets. Remove spark plugs.
(2) Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke.
(3) Remove rocker arms with rocker shafts and install dummy shafts. (The rocker arms should not be disturbed and left on shafts.)
(4) With air hose attached to cylinder air pressure adapter tool installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa), to hold valves in place when springs are removed.
(5) Using Tool C-4682 (Fig. 13) compress valve spring only enough to remove retainer valve locks.
CAUTION: Do not pinch seal between retainer and top of guide. Remove valve spring and inspect valve seal for proper seating and possible damage. Install new spring. Reinstall the valve retainer locks. Compress the spring only enough to install the locks. Remove adapter tool. Replace other valve spring on number 1 cylinder in same way.
(6) Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being removed.
(7) Remove dummy shafts and install rocker shafts with rocker arms and torque screws to 28 N-m (250 in.lbs.)
(8) Install valve covers using new gaskets and torque screws to 14 N-m (120 in.lbs.).
Installation
(1) Reinstall spark plugs and torque to 30 ft.lbs. (41 N-m).
(2) Make sure the injector holes are clean and all plugs have been removed. Replace O-rings if damaged.
(3) Lube injector O-ring with a drop of clean engine oil to ease installation.
Figure 12 - Fuel Rail Removal:
(4) Reinstall fuel rail. Put the tip of each injector into its port. Push the assembly into place until the injectors are seated in the ports (Fig. 12).
Figure 9 - Fuel Rail Attaching Bolts:
(5) Install the (4) fuel rail attaching bolts and torque to 22 N-m (200 in.lbs.) (Fig. 9).
(6) Install fuel tube retaining bracket screw and torque to 4 N-m (35 in.lbs.) (Fig. 9).
(7) Reconnect cam sensor, coolant temperature sensor and engine temperature sensors.
Figure 11 - Fuel Injector Wiring Clip:
(8) Install fuel injector harness wiring clips on the alternator bracket and intake manifold water tube (Fig. 11).
(9) Connect fuel pressure regulator vacuum line.
(10) Remove covering on lower intake manifold and clean surface.
(11) Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight.
(12) Install the alternator bracket to intake plenum bolt and the cylinder head to intake manifold strut bolts. (Do not torque.)
Figure 8 - Intake Manifold Bolts:
(13) Torque intake plenum bolts to 28 N-m (250 in.lbs.) following torque sequence in (Fig. 8).
Figure 7 - Ignition Coils:
(14) Torque alternator bracket to intake plenum bolt to 54 N-m (40 ft.lbs.) (Fig. 7).
Figure 5 - Electrical and Vacuum Connections To Intake Manifold:
(15) Torque the cylinder head to intake plenum strut bolts to 54 N-m (40 ft. lbs.) (Fig. 5).
Figure 6 - MAP Sensor Electrical Connector:
(16) Connect ground strap, MAP and heated oxygen sensor electrical connectors (Fig. 6).
Figure 5 - Electrical and Vacuum Connections To Intake Manifold:
(17) Connect charge temperature sensor electrical connector (Fig. 5).
(18) Connect vacuum harness to intake plenum (Fig. 5). Connect PCV system and brake booster hose.
(19) On California models, using a new gasket from the parts package, connect the EGR tube flange to the intake manifold and torque to 22 N-m (200 in.lbs.).
(20) Clip wiring harness into the holes in the throttle cable bracket and intake manifold water tube bracket.
Figure 4 - Electrical and Vacuum Connection to Throttle Body:
(21) Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor (Fig. 4).
(22) Connect vacuum harness to throttle body (Fig. 4).
Figure 7 - Ignition Coils:
(23) Install the direct ignition system (DIS) coil module. Torque fasteners to 12 N-m (105 in.lbs.) (Fig. 7).
(24) Reconnect 4-way electrical connector to DIS coil module and reconnect spark plug wires.
Figure 10 - Quick Connect Fuel Fittings to Fuel Rail:
(25) Install fuel hose quick connector fittings to fuel rail. Push the fittings onto the rail until they click into place. Fuel supply fitting is 5/16" and fuel return fitting is 1/4 inch (Fig. 10).
Figure 3 - Throttle Cable Attachment:
(26) Install throttle and cruise control cables to the bracket and throttle body. (Fig. 3).
Figure 1 - Throttle Body Assembly 3.3L:
(27) Reconnect the 2 injector harness electrical connectors to main harness.
(28) Install air cleaner cover and hose assembly (Fig. 1).
(29) Reconnect negative battery cable.
(30) Replace fuel tank filler cap.
(31) With the DRBII use ASD Fuel System Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay will remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the "Off" position.