Tools Required

1. Remove the 2 nuts (2) from the intake manifold sight shield (1).
2. Remove the sight shield (1) from the engine.
3. Partially drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



4. Position the J 38185  (2) to the clamp in order to remove the radiator inlet hose (1) from the water housing crossover.



5. Disconnect the PCV fresh air tube (1) from the camshaft cover.
6. Remove the Ignition coil cassette. Refer to Ignition Control Module Replacement - Bank 1 in Engine Controls - 4.0 L.



7. Remove the 4 spark plug boots.
8. Disconnect the cable harness clips at the front of the camshaft cover and position the cable harness aside.
9. Remove the secondary AIR valve bracket nut closest to the center of the engine.
10. Pry outward slightly on the secondary AIR valve bracket in order to gain clearance to remove the water pump drive belt shield nut.



11. Remove the water pump drive belt shield fasteners.
12. Remove the water pump drive belt shield.
13. Disconnect the water pump drive belt.



14. Loosen the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.
15. Remove the water pump belt tensioner (1).



16. Remove the plastic dust cap from the end of the intake camshaft.



17. Remove the water pump drive pulley from the intake camshaft using the J 38825 .



18. Remove the 3 camshaft seal retainer bolts.




Important: DO NOT reuse the camshaft seal.

19. Remove the camshaft seal.



20. Remove the 9 camshaft cover bolts.



21. Lift the camshaft drive end of the camshaft cover up.



22. Remove the camshaft cover reward to clear the water pump drive shaft.
23. Discard the camshaft cover perimeter seals and spark plug seals if there is any evidence of damage or if the seal comes out of the groove in the cover during removal.
24. Clean and inspect the camshaft cover. Refer to Camshaft Cover Cleaning and Inspection in Engine Mechanical - 4.0 L Unit Repair.

1. Install the camshaft cover seal as required.

Important: Be careful to prevent the exposed section of the camshaft cover seal from being damaged by the edge of the cylinder head casting.




2. Insert the intake camshaft end through the hole in the camshaft cover.



3. Work the camshaft cover into position by pivoting the cover down and to the left allowing the cover to clear the camshaft drive chain and then aligning the bolt holes.




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.

4. Install the 9 camshaft cover bolts.

Tighten
Tighten the camshaft cover bolts to 10 N·m (89 lb in).




5. Install the NEW seal as follows:

5.1.	Lubricate the camshaft seal lips with engine oil.

5.2.	Push the camshaft seal into position around the intake camshaft using the protective sleeve supplied with the seal.




6. Coat the bolt threads with sealant GM P/N 1052080 (Canadian P/N 10953480) or equivalent.
7. Install the camshaft seal (1) bolts.

Tighten
Tighten the camshaft seal bolts to 3 N·m (27 lb in).




8. Place the water pump drive pulley in position on the intake camshaft.



9. Install the water pump pulley using the J 38823 . During installation, the tool will bottom out on the camshaft at the proper depth.



10. Install the plastic dust cap into the end of the camshaft.



11. Position the water pump belt tensioner (1) to the water crossover.

Tighten
Tighten the water pump belt tensioner bolts (3) to 10 N·m (89 lb in).




12. Connect the water pump drive belt.
13. Install the water pump drive belt shield.
14. Install the water pump drive belt shield fasteners.

Tighten

•	Tighten the water pump drive belt shield fasteners to 10 N·m (89 lb in).

•	Tighten the secondary AIR valve bracket nut to 9 N·m (80 lb in).

15. Connect the cable harness clips to the cable harness at the front of the camshaft cover.



16. Install the spark plug boots onto the coil cassette.

Ensure that the boots are fully seated against the cassette.

17. Install the ignition coil cassette. Refer to Ignition Control Module Replacement - Bank 1 in Engine Controls - 4.0 L.



18. Connect the PCV fresh air tube (1) to the left camshaft cover.



19. Position the J 38185  (2) to the clamp in order to connect the radiator inlet hose (1) to the water housing crossover.



20. Position the intake manifold sight shield (1) to the engine.
21. Install the 2 intake manifold sight shield nuts (2).

Tighten
Tighten the nuts to 3 N·m (27 lb in).

22. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.