Removal
Cylinder Heads
Special Tool(s)
1. Remove the engine.
2. Remove the bolts and the flywheel.
3. Remove the engine/transmission spacer plate.
4. Mount the engine on a workstand.
5. Remove the special tools.
6. Remove the bolts and the RH engine mount.
7. 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.
8. Disconnect the electrical connectors from the fuel pulse damper, exhaust gas recirculation (EGR) vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
9. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
10. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator.
11. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
12. Disconnect the vacuum hose from the EGR valve.
13. Disconnect the vacuum hoses at the back of the supercharger and remove the vacuum harness.
14. Remove the vacuum accessory bracket mounting nut.
15. Remove the mounting bolts and the vacuum accessory bracket.
16. Remove the positive crankcase ventilation (PCV) valve.
17. Disconnect and remove the PCV hose.
18. Disconnect the barometric pressure (BARD) sensor electrical connector.
19. Disconnect the EGR tube from the exhaust manifold.
20. NOTE: Discard the EGR valve gasket.
Remove the EGR valve and tube as an assembly.
21. Disconnect the electrical connectors and remove the LH ignition coils.
22. Disconnect the electrical connectors and remove the RH ignition coils.
23. Disconnect the camshaft position (CMP) sensor electrical connector.
24. Disconnect the engine coolant temperature (ECT) sensor electrical connector and unclip the harness.
25. NOTE: LH shown, RH similar.
Disconnect the two radio ignition interference capacitor electrical connectors.
26. Remove the fuel charging wiring harness bracket bolt.
27. Disconnect the crankshaft position (CKP) sensor electrical connector.
28. Disconnect the A/C compressor electrical connector.
29. Unclip the harness from the bracket.
30. Remove the harness support bracket.
31. Disconnect the eight fuel injectors.
32. Separate the harness from the fuel supply manifold studs in four places and remove the fuel charging wiring harness.
33. NOTE: The intake manifold gaskets are reusable if undamaged.
Remove the ten bolts and the intake manifold, and the supercharger and fuel supply manifold as an assembly.
34. Remove the bolts and the heater coolant outlet tube.
35. NOTE: LH shown, RH similar.
Remove the coolant bypass studs.
36. NOTE: LH shown, RH similar.
Remove the bolts and the coolant bypass tube.
37. NOTE: LH shown, RH similar.
Remove the eight spark plugs.
38. 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 old sealant.
Remove the fasteners and the LH valve cover. Remove and discard the gasket, clean and inspect the sealing surfaces.
39. 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 old sealant.
Remove the fasteners and the LH valve cover. Remove and discard the gasket, clean and inspect the sealing surfaces.
40. Remove the supercharger belt idler support bracket assembly.
41. Remove the accessory drive belt.
42. Remove the bolts and the coolant pump pulley.
43. Remove the bolt.
44. Using the special tool, remove the crankshaft pulley.
45. Using the special tools, remove the crankshaft front oil seal.
46. Remove the bolts and the generator.
47. Remove the bolts and the generator support bracket.
48. Remove the power steering pressure hose.
49. Remove the bolts and the power steering pump.
50. Remove the four bolts.
51. Remove the bolt and the idler pulley.
Part 1 Of 2:
Part 2 Of 2:
52. 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 old sealant.
Remove the bolts and the engine front cover.
^ Remove the engine front cover gasket.
^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the mating surfaces.
53. Remove the crankshaft position sensor pulse wheel.
54. CAUTION: Mark roller follower positions. Reused roller 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.
55. Using the special tool, compress the intake valve spring and remove the roller follower.
56. Using the special tool, compress the exhaust valve spring and remove the roller follower.
57. Repeat the above 3 steps to remove all the necessary roller followers. Inspect the roller followers and camshafts.
58. Rotate the crankshaft until the crankshaft keyway points towards the top of the engine (12 o'clock).
59. Remove the bolts and the RH and LH timing chain tensioners.
60. Remove the RH and LH timing chain tensioner arms.
61. Remove the RH and LH timing chains and the crankshaft sprocket.
62. Remove the bolts and the RH and LH timing chain guides
63. Remove the exhaust manifold.
1. Remove the nuts.
2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket and discard.
64. Remove the bolt and oil level indicator tube.
65. Remove the exhaust manifold.
1. Remove the nuts.
2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket and discard.
66. Clean and inspect the exhaust manifolds.
67. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record the hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
68. 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 a tighten-to-yield design and cannot be reused.
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: 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.
69. 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 a tighten-to-yield design and cannot be reused.
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: 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.
70. 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 the 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.
71. 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 than 0.0254 mm (0.001 inch).