Removal
All Cylinder Heads
1. Remove the engine. Service and Repair
2. Remove the bolts and the flywheel.
3. Remove the spacer plate.
4. Lower the engine onto the wooden blocks.
5. Remove the special tool.
6. Remove the LH exhaust manifold.
1. Remove the eight nuts.
2. Remove the manifold and discard the gasket.
7. Remove the stud and the oil level indicator and tube.
8. NOTE: LH shown, RH similar.
Install the special tools on the LH and RH sides of the engine.
9. Mount the engine on a work stand.
10. Remove the RH engine mounts.
11. NOTE: LH shown, RH similar.
Remove the cylinder block drain plugs, and drain the coolant in a suitable container. Install the drain plug when finished.
12. Disconnect the oil pressure sender.
13. Remove the oil fill tube.
14. Remove the bolts and the LH ignition coil cover.
15. Remove the bolts and the RH ignition coil cover.
16. Disconnect the LH ignition coils.
17. Disconnect the RH ignition coils.
18. Remove the eight ignition coils.
19. Disconnect the camshaft position (CMP) sensor.
20. Disconnect the cylinder head temperature (CHT) sensor.
21. Remove the nuts, bracket and ground strap.
22. Disconnect the knock sensor (KS).
23. Separate the engine control sensor wiring from the engine at six locations and remove the wiring.
24. Remove the water pump pulley.
1. Remove the bolts.
2. Remove the pulley.
25. Remove the bolt.
26. Using the special tool, remove the crankshaft damper.
27. Using the special tool, remove the front crank seal.
28. Remove the bolt and the belt idler pulley.
29. NOTE: LH shown, RH similar.
Remove the eight spark plugs.
30. 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.
NOTE: LH shown, RH similar.
Remove the bolts, studs and the valve covers.
Remove the gaskets. Clean and inspect the sealing surfaces.
31. 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 studs, bolts, and the engine front cover. Remove the gaskets, clean and inspect the sealing surfaces.
32. CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized.
Remove the crankshaft sensor ring from the crankshaft.
33. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
34. Using the special tool, compress the intake valve springs and remove the roller followers.
35. Using the special tool, compress the exhaust valve springs and remove the roller followers.
36. Repeat the above three steps to remove all the necessary roller followers. Inspect the roller followers and camshafts.
37. Rotate the crankshaft until the crankshaft keyway points towards the top of the engine (12 o'clock).
38. NOTE: LH shown, RH similar.
Remove the two bolts, the timing chain tensioner and tensioner arm.
39. NOTE: LH shown, RH similar.
Remove the LH and RH timing chains and the crankshaft sprocket.
- Remove the timing chains from the camshaft sprockets.
Remove the right and left timing chains and the crankshaft sprocket from the crankshaft.
40. CAUTION: The bolts are different lengths and must be returned to their original location. NOTE: RH shown, LH similar.
Remove the bolts and the timing chain guides.
RH Cylinder Head
41. Remove the RH exhaust manifold.
1. Remove the eight nuts.
2. Remove the exhaust manifold and gasket.
Both Cylinder Heads
42. Clean and inspect the exhaust manifolds.
43. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
RH Cylinder Head
44. 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 the sealing surfaces. These tools cause scratches and gouges that 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
45. 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 the sealing surfaces. These tools cause scratches and gouges that 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
46. 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 that 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 surfaces is normal.
47. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) 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 the straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).