Part 1

Cylinder Head

Special Tool(s):

Material:

Removal (Steps 1-32)

Cylinder heads
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the engine.
3. Remove the bolts and the flexplate.





4. Remove the engine/transmission spacer plate.





5. Mount the engine on a suitable engine stand.





6. Remove the LH and the RH lifting brackets.





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.
^ To install, tighten to 20 Nm (15 ft. lbs.)





9. Remove the bolt and the battery cables from the engine.





10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.





11. Disconnect the 8 ignition coil electrical connectors.





12. Disconnect the 8 fuel injector electrical connectors.





13. Remove the bolts and the intake manifold shield.





14. Remove the crankcase ventilation tube.





15. Remove the generator mounting bracket.
^ Remove the bolts.
^ Remove the bracket.





16. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.





17. Disconnect the generator electrical connector.





18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.





19. Remove the generator wiring harness anchor from the LH front stud.





20. Disconnect the ground wire from the RH rear stud.





21. Disconnect the camshaft position (CMP) sensor electrical connector.





22. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.





23. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.





24. Disconnect the EGR tube nut from the EGR system module.





25. Remove the generator.
1 Remove the bolts.
2 Remove the generator.





26. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





27. Remove the intake manifold crash bracket stud bolt.





28. Remove the 8 bolts and the 8 ignition coils.





29. Remove the 2 bolts and the coolant outlet adapter.





30. Remove the thermostat.





31. Remove the bolts and the intake manifold.





32. Remove the intake manifold gaskets and discard.