Service Procedure - Engine Cylinder Head Removal
1. Install protective covering to the front of the vehicle. This is to protect the grille from damage.2. Install fender covers.
3. Bleed the fuel pressure. Refer to Fuel Pressure Relief in the Service Manual.
4. Remove the air cleaner resonator, the outlet duct, and the air cleaner assembly.
^ Refer to Air Cleaner Resonator and Outlet Duct Replacement Removal in the Service Manual.
^ Refer to Air Cleaner Assembly Replacement in the Service Manual.
5. Remove the battery from the vehicle. Refer to Battery Replacement in the Service Manual.
6. Disconnect the Fuel/EVAP lines from the intake manifold and move aside (includes fuel line removal from fuel rail). Refer to Evaporative Emission Hoses/Pipes Replacement - Engine in the Service Manual.
7. Remove the bolt holding the oil indicator (dipstick) tube to the intake manifold and move the oil dipstick aside (Do not remove).
8. Drain the engine coolant. Refer to Draining and Filling Cooling System (Static Fill) in the Service Manual.
9. Lift the Vehicle. Refer to Lifting and Jacking the Vehicle in the Service Manual.
10. Remove the bolts holding the engine shield.
11. Remove the engine shield from the vehicle.
12. Remove the bolts holding the oil pan skid plate.
13. Remove the oil pan skid plate from the vehicle.
14. Remove the drive belt.
15. Drain the engine oil.
16. Remove left front tire and wheel.
17. Remove the left front wheelhouse panel. Refer to Wheelhouse Panel Replacement (Front) in the Service Manual.
18. Remove the fir tree wiring harness connectors from the engine wiring harness bracket from the left front wheelhouse opening.
19. Remove the intake manifold bolts from the wheelhouse access (bolts stay with intake manifold). On two-wheel drive vehicles, the intake manifold bolts are removed from the top of the engine, not through the left front wheelhouse panel.
20. Lower the vehicle.
21. Remove the PCV pipes from the cam cover and remove the intake manifold from the vehicle.
22. Remove the generator output BAT terminal nut.
23. Remove the generator lead from the generator.
24. Disconnect the generator electrical connector.
25. Remove the generator bolts and set the generator aside. The generator does not have to be removed from the vehicle. On a two-wheel drive vehicle, the generator must be removed from the vehicle.
26. Disconnect the A/C pipe clamp from the engine lift hook bracket.
27. Remove the engine lift hook bracket bolts and bracket from the vehicle.
28. Remove the bolts holding the windshield washer solvent container and coolant recovery reservoir to the right inner fender. Move aside to gain access to the engine wiring harness to PCM.
29. Disconnect the following cross-vehicle engine wiring harness connectors:
^ PCM
^ Engine Coolant Temperature Sensor
^ MAP Sensor
^ Ignition Coils
^ Harness clamps at power steering pump
^ Wiring Harness fastener at right front inner fender
^ Throttle Body
^ Camshaft Sensors
^ Exhaust Camshaft Actuator
^ Fuel Injectors
^ HO2S # 1
^ Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
30. Remove the A.I.R. injection pipe block-off plate bolts from the cylinder head.
31. Remove the A.I.R. injection pipe block-off plate.
32. Remove the bolts from the exhaust manifold heat shield.
33. Remove the exhaust manifold heat shield.
34. Remove the exhaust manifold bolts.
35. Move the exhaust manifold back and away from the cylinder head.
36. Remove the bolts to all ignition coil assemblies and remove all ignition coil assemblies from the cam cover.
37. Remove all the spark plugs from the cylinder head.
38. Remove the cam cover bolts.
39. Remove the cam cover from the cylinder head.
40. Remove the upper radiator hose and clamp from the cylinder head.
IMPORTANT:
Before performing one of the TDC procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexs to hold the camshaft from turning. Do Not remove the bolts. Refer to figure 1.
41. Perform the following service timing procedure.
42. Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder. Refer to figure 2 and 3. The TDC indicator tool graduation marks on the shaft should note top of the piston stroke. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. There may be a variation of build and the straight edge may not lay perfectly flat across back of the camshafts. Refer to figure 4.
IMPORTANT:
Do not rotate the engine counterclockwise to find TDC, as this will put slack in the camshaft actuator and the timing chain. If the engine is rotated counterclockwise, even a small amount, then the engine should be rotated at least 90 degrees and then brought back to TDC by rotating clockwise only.
IMPORTANT:
The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up.
43. Once TDC is located for the number 1 cylinder using above methods, raise the vehicle and lock the flywheel with Kent Moore EN-46547 - Flywheel Holding Tool. Refer to figure 5.
44. Use a metal scribe, or equivalent, to place a reference mark on the harmonic balancer to the front cover for alignment purposes (White Paint Pen is for demonstration purposes only). Refer to figure 6.
45. Lower the vehicle.
CAMSHAFT HOLDING TOOL CAUTION:
The camshaft holding tools must be installed on the camshafts to prevent camshaft rotation. When performing service to the valve train and/or timing components, valve spring pressure can cause the camshafts to rotate unexpectedly and can cause personal injury.
IMPORTANT:
If the timing is correct (TDC compression stroke number 1 cylinder), the camshaft flats will be in the up position.
46. Install the Kent Moore Camshaft Holding Tool J-44221 to the back of the camshafts. Refer to figure 7.
47. Remove the upper timing chain guide to the cylinder head (not found on later vehicles).
IMPORTANT:
The exhaust camshaft actuator must be fully advanced before scribing your reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. There may be some normal play in the exhaust camshaft actuator itself. To ensure camshaft actuator is fully advanced, do not rotate engine counterclockwise when finding TDC # 1.
48. Clean the timing chain and gears with Brake Cleaner or suitable solvent. Use a metal scribe or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark the location prior to disassembly. It is recommended that a metal scribe or equivalent be in the 12:00 position (White Paint Pen for demonstration purposes only). Refer to figure 8.
IMPORTANT:
Figure 9 shows the front cover removed for demonstration purposes only.
IMPORTANT:
Refer to Service News "Supplement To Bulletin SB07-01-S002 - User Tips for EN48464" a supplement to this bulletin
NOTE:
DO NOT use excessive force to seat the wedge tool. If excessive force is used, you may damage the timing chain tensioner or break the front cover bolt requiring complete disassembly of the front engine.
49. Install Kent Moore EN-48464 - Lower Timing Chain Tensioner Holding Tool per figure 10. This wedge tool will hold the timing chain and tensioner in position. It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain. Refer to figure 11. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer. Refer to figure 12.
50. Once the tool is correctly installed, unscrew the handle and remove the handle. Refer to figure 13.
IMPORTANT:
Figure 13 shows the front cover removed for demonstration purposes only.
51. Remove (1 long and 2 short) cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
IMPORTANT:
Use a 25 mm (1 in) open end wrench on the camshaft hexs to hold the camshaft from turning. It is critical that the crankshaft does not move and is held at TDC when the intake and exhaust camshaft sprocket bolts are removed.
IMPORTANT:
If the crankshaft is not held in place, the wedge tool could be dislodged. If the crankshaft moves, or if the tool is not seated properly allowing the timing chain tensioner to extend, the repair will have to be completed by removing the front cover to release the timing chain tensioner.
52. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
53. Remove both upper timing chain tensioner shoe bolts.
54. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.
55. Carefully remove the exhaust and intake camshaft sprockets from the exhaust and intake camshafts while still engaged with the timing chain. Refer to figure 14 which shows the exhaust camshaft sprocket already removed.
56. Remove the sprockets from the chain, tie a piece of mechanics wire on the timing chain and let it drop. Refer to figure 15.
57. Remove the cylinder head bolts from the cylinder head. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. Once the bolts are removed, discard them. Refer to figure 16.
Important:
Refer to Service Bulletin IB07-01-S001 for additional information on Torque to Yield Bolt Breakage.
58. Remove the cylinder head from the vehicle.
59. Disassemble the cylinder head. Refer to the Service Manual for the following cylinder head procedures:
^ Cylinder Head Disassemble. The following components will have to be removed when disassembling the cylinder head. Refer to the Service Manual for the following service procedures:
^ Engine Coolant Temperature Sensor Replacement
^ Intake Camshaft Position Sensor Removal / Installation
^ Exhaust Camshaft Sensor Removal / Installation
^ Camshaft Position Actuator Solenoid Valve Removal / Installation
^ Water Outlet Removal / Installation
^ Valve Rocker Arm and Valve Lash Adjusters Removal / Installation
^ Cylinder Head Cleaning and Inspection
^ Cylinder Head Assembly. Refer to the above service procedure for assembly.