Removal
Cylinder Heads
Special Tool(s)
Removal
Both cylinder heads
1. Remove the engine.
Manual transmission vehicles
2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate damage.
NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel.
Remove the bolts and remove the clutch pressure plate and the clutch disc.
All vehicles
3. Remove the flywheel or flexplate.
4. Remove the engine/transmission spacer plate.
5. Mount the engine on a work stand.
6. Remove the special tools.
7. Remove the bolts and the RH engine mount.
8. NOTE: LH shown, RH similar.
Remove the drain plugs from the engine block. Allow the coolant to completely drain.
^ Install the drain plugs when finished.
9. Disconnect the positive crankcase ventilation (PCV) tube.
10. Disconnect the electrical connector and remove the PCV valve tube.
11. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
12. Disconnect the EGR tube from the exhaust manifold.
13. Disconnect the fuel pressure damper electrical connector.
14. Disconnect the eight fuel injector electrical connectors.
15. Remove the LH coil cover.
16. Remove the RH coil cover.
17. Disconnect the LH ignition coil electrical connectors.
18. Disconnect the RH ignition coil electrical connectors.
19. Remove the eight ignition coils.
20. Disconnect the generator.
21. Disconnect the idle air control (IAC) valve.
22. Disconnect the throttle position (TP) sensor.
23. Remove upper intake manifold in the sequence shown.
24. Remove the upper intake manifold gasket.
^ Clean and inspect the sealing surfaces.
25. Disconnect the engine coolant temperature (ECT) sensor.
26. Disconnect the knock (KS) sensor jumper harness from the fuel charging harness.
27. Remove the accessory drive belt.
28. Remove the coolant bypass tube and the upper generator support bracket.
^ Remove the bolts.
^ Remove the coolant bypass tube.
^ Remove the upper generator support bracket.
29. Remove the generator.
30. Remove the three bolts from the power steering reservoir.
31. Remove the bolts and the power steering pump.
32. Remove the eight bolts and the two studs in the sequence shown. Remove the lower intake manifold.
33. Remove the intake manifold gaskets.
34. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths.
Clean the sealing surfaces.
35. Remove the KS harness.
1. LH KS connector.
2. RH KS connector.
3. Engine control sensor wiring connector.
4. Fuel injector connector.
5. A/C compressor connector.
6. Crankshaft position (CKP) sensor connector.
36. Remove the coolant pump pulley.
1. Remove the bolts.
2. Remove the coolant pump pulley.
37. Remove the bolt.
38. Using the special tool, remove the crankshaft pulley.
39. Using the special tool, remove the crankshaft front seal.
40. Remove the belt idler pulleys.
41. NOTE: LH shown, RH similar. Remove the eight spark plugs.
42. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Remove and discard the gasket, clean and inspect the sealing surfaces.
Remove the bolts and the LH valve cover.
43. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Remove and discard the gasket, clean and inspect the sealing surfaces.
Remove the bolts and the RH valve cover.
LH cylinder head
44. Remove the LH exhaust manifold.
1. Remove the nuts.
2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket and discard.
45. Remove the bolt and the oil level indicator tube.
46. Disconnect the coolant bypass tube.
1. Remove the nut.
2. Remove the tube.
RH cylinder head
47. Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket and discard.
Both cylinder heads
48. Clean and inspect the exhaust manifolds.
49. Remove the four bolts.
Part 1 Of 2:
Part 2 Of 2:
50. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean and inspect the mating surfaces.
Remove the bolts and the engine front cover.
51. Remove the CKP sensor pulse wheel.
52. CAUTION: Mark the roller follower positions. Reused followers must be installed in their original locations.
Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
53. Using the special tool, compress the intake valve spring and remove the roller follower.
54. Using the special tool, compress the exhaust valve spring and remove the roller follower.
55. Repeat the above three steps to remove all the necessary roller followers. Inspect the roller followers and camshafts.
56. Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).
57. Remove the bolts and the RH and LH timing chain tensioners.
58. Remove the RH and LH timing chain tensioner arms.
59. Remove the RH and the LH timing chains and crankshaft sprockets.
60. Remove the RH and LH timing chain guides.
61. NOTE: The hydraulic lash adjusters must be reinstalled in their original location. Record the hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
RH cylinder head
62. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the RH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
LH cylinder head
63. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the LH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
Both cylinder heads
64. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surface is normal.
65. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.
Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more then 0.0254 mm (0.001 inch).