Cylinder Head Removal

^ Tool Required:
- J 441040 Camshaft Sprocket Spanner Wrench, Or Equivalent

1. Negative (-) battery cable.
2. Release fuel pressure.
3. Fuel filler cap to release fuel vapor pressure in fuel tank. After releasing pressure, replace cap.
4. Drain cooling system.
5. Air intake pipe from Air cleaner intake hose and throttle hose.
6. Three bolts and throttle cover from intake manifold.





7. Accelerator cable and kickdown cable (automatic transmission equipped vehicles) from throttle body bellcrank.
8. One bolt, one nut, one screw and accelerator cable bracket from throttle body.





9. The following electrical connectors:
^ Throttle Position (TP) sensor.
^ Intake Air Control (IAC) valve.
^ Engine Coolant Temperature (ECT) sensor.
^ ECT sending unit.
^ Air Conditioning Engine Coolant Temperature (A/C ECT) switch (A/C equipped vehicles only).
^ EVAP canister purge valve.
^ EGR temperature sensor.
^ EGR solenoid vacuum valve.
^ EGR by-pass valve.
^ Fuel injectors.
^ Engine ground wire from intake surge tank.
10. The following vacuum hoses:
^ EVAP canister purge valve.
^ Vacuum modulator supply hose (automatic transmission equipped vehicles).
^ Brake booster supply hose.
^ EGR valve.
^ EGR valve modulator.
^ MAP sensor hose.
11. Coolant hose from IAC valve.
12. IAC hose from IAC valve.
13. Coolant hoses from the fast idle air valve below throttle body.





14. Fuel feed hose at fuel feed hose union.
15. Fuel return hose from fuel return line.
16. PCV hose from PCV valve.
17. Loosen upper radiator hose clamp at thermostat housing.
18. Upper radiator hose from thermostat housing.
19. Coolant bypass hose from intake manifold.





20. One bolt, one nut and generator adjusting arm bracket from intake manifold.





21. Two bolts and front intake manifold reinforcement bracket from intake manifold.
22. Two bolts and rear intake manifold reinforcement bracket from intake manifold.
23. Two bolts and lower intake manifold support bracket from intake manifold.
24. Eight nuts, three bolts, intake manifold with gasket, intake surge tank and throttle body from cylinder head.





25. Two nuts, three bolts and upper exhaust manifold heat shield from exhaust manifold.
26. Raise and suitably support vehicle.





27. Two bolts, one nut and exhaust manifold reinforcement bracket from exhaust manifold and engine block.
28. Two bolts and lower exhaust manifold heat shield from exhaust manifold.





29. Three bolts and front pipe/Three Way Catalytic Converter (TWC) assembly with gasket from exhaust manifold.
30. Lower vehicle.








31. Nine nuts and exhaust manifold with gasket and engine hanger from cylinder head.
32. Loosen upper and lower A/C compressor mounting bolts (if equipped).
33. Loosen upper and lower power steering pump mount bolts.
34. A/C compressor (if equipped) and/or power steering drive belt from pulleys.
35. Loosen upper and lower generator mounting bolts.
36. Generator/coolant pump drive belt from pulleys.
37. Four nuts, cooling fan and coolant pump pulley from coolant pump.
38. Raise and suitably support vehicle.
39. Four bolts and front skid plate from undercarriage (if equipped).
40. Two lower radiator shroud bolts.
41. Lower vehicle.
42. Two bolts from A/C suction line brackets at right side of radiator core support (if equipped) and carefully reposition suction line for radiator shroud removal access.
43. Two upper radiator shroud bolts and radiator shroud from radiator.

NOTE:
^ If radiator shroud is difficult to remove, drain the cooling system and disconnect the upper radiator hose from the radiator to gain access.
^ It is not necessary to remove the crankshaft pulley center bolt when removing the crankshaft pulley.





44. Five bolts and crankshaft pulley from crankshaft.
45. Oil pressure sending unit wire conduit from timing belt cover.
46. Eight bolts, one nut and timing belt cover from engine.





^ NOTE: There are two sets of timing marks which must be aligned to ensure correct engine timing upon timing belt installation. A notch in the camshaft timing belt gear designated as E must be aligned with the notch in the cylinder head cover. A punch mark on the crankshaft timing belt gear should then align with the arrow in the oil pump casting. Make sure to align both sets of marks prior to timing belt removal to ensure correct timing belt installation and engine timing.

47. Align the timing marks on the cylinder head cover and camshaft timing belt gear. This should also align the timing marks on the oil pump casting and crankshaft timing belt gear.





48. Loosen the timing belt tensioner bolt.
49. Timing belt tensioner spring from timing belt tensioner plate.
50. Timing belt from camshaft and crankshaft timing belt gears.





51. One bolt and camshaft timing belt gear from camshaft using a camshaft sprocket spanner wrench to hold the camshaft timing belt gear stationary.





52. Two bolts and inside timing belt cover from cylinder head.
53. Two bolts and A/C mounting bracket with compressor from cylinder head.
54. Distributor from distributor case.





55. Six bolts and cylinder head cover from cylinder head.
56. Cylinder head cover gasket and O-rings from cylinder head cover.

NOTE: A small amount of oil may drain from the distributor case upon removal from the cylinder head. Place a suitable container underneath the distributor case or use a shop towel to catch and absorb oil.





57. Three bolts and distributor case from cylinder head.





58. Loosen all valve adjusting screw locknuts.
59. Loosen all valve adjusting screws until all rocker arms move freely.





CAUTION: Always loosen the camshaft carrier bolts gradually in the order shown, in order to relieve tension on the camshaft. If the camshaft carrier bolts are removed at random, damage to the camshaft may occur.

60. Twelve bolts, camshaft carrier caps, camshaft seal and camshaft from cylinder head.





NOTE: Loosen the cylinder head bolts gradually in the sequence shown, to prevent cylinder head distortion.





61. Ten bolts, cylinder head and cylinder head gasket from cylinder block.
^ Clean:
- Mating surfaces of cylinder head, cylinder block, intake manifold, exhaust manifold, and distributor gear case of all gasket or sealant materials.
- All bolt threads and bolts.





62. Oil jet in cylinder head for any obstructions and ensure that the oil jet is tightened to its torque specification.
^ Tighten the oil jet to 5 Nm (44 inch lbs.).