Cylinder Head - Removal
Cylinder Head
Removal
Cylinder heads
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.
2. Remove the engine. For additional information, refer to Engine Engine - Removal in the Removal information.
3. Remove the bolts and the flexplate.
4. Remove the engine/transmission spacer plate.
5. Using the Engine Lifting Bracket Set, mount the engine on a suitable engine stand.
6. If equipped with cylinder block drain plugs, remove the bolts and the RH engine mount.
7. NOTE: LH shown, RH similar.
If equipped, 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 (177 lb-in).
8. Remove the bolt and the battery cables from the engine.
9. Disconnect the EGR tube from the exhaust manifold.
10. Disconnect the 8 ignition coil electrical connectors (4 shown).
11. Disconnect the 8 fuel injector electrical connectors (4 shown).
12. Remove the bolts and the intake manifold shield.
13. Remove the crankcase ventilation tube.
14. Disconnect the generator electrical connector and detach the wire harness retainers.
15. Remove the generator mounting bracket.
- Remove the 4 bolts.
- Remove the bracket.
16. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
17. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
18. Disconnect the Camshaft Position (CMP) sensor electrical connector.
19. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
20. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
21. Disconnect the EGR tube nut from the EGR system module.
22. Remove the generator.
1. Remove the 2 bolts.
2. Remove the generator.
23. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
24. Remove the intake manifold crash bracket stud bolt.
25. Remove the 8 bolts and the 8 ignition coils (4 shown).
26. Remove the 2 bolts and the coolant outlet adapter.
27. Remove the thermostat.
28. Remove the bolts and the intake manifold.
- Discard the intake manifold gasket.
29. Remove the cylinder head insert from the LH cylinder head.
30. NOTICE: 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.
Clean the sealing surfaces.
31. Remove the coolant bypass tube.
1. Remove the retaining nut.
2. Remove the ground strap.
3. Remove the coolant bypass tube.
32. Loosen the studs and bolts and remove the LH valve cover.
- Clean the mating surface and discard gasket.
33. Loosen the studs and bolts and remove the RH valve cover.
- Clean the mating surface and discard the gasket.
34. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Remove the spark plugs.
35. Position the lobe of the camshaft up.
36. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
37. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
Use the Valve Spring Compressor to compress the valve springs and remove the camshaft roller followers.
38. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
Remove the 16 hydraulic lash adjusters (4 shown).
39. Remove the bolt and the belt idler pulley.
40. Remove the coolant pump pulley.
41. Remove the crankshaft pulley bolt.
42. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
43. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
44. Remove the front 4 oil pan bolts.
45. NOTE: Correct fastener location is essential for the installation. Record fastener location.
Remove the 15 fasteners in the sequence shown.
46. Remove the engine front cover from the cylinder block.
- Clean the sealing surfaces and discard the gaskets.
47. Remove the crankshaft sensor ring.
48. Position the crankshaft with the keyway at the 12 o'clock position.
49. NOTE: LH shown, RH similar.
Remove the timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.
50. Remove the LH and RH timing chains and the crankshaft sprocket.
- Remove the RH timing chain from the camshaft sprocket.
- Remove the RH timing chain from the crankshaft sprocket.
- Repeat for the LH timing chain and crankshaft sprocket.
51. Remove both timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.
RH cylinder head
52. Remove the RH exhaust manifold.
1. Remove the nuts and discard.
2. Remove the RH exhaust manifold.
3. Remove and discard the RH exhaust manifold gasket.
53. Remove and discard the 8 RH exhaust manifold studs.
LH cylinder head
54. Remove the LH exhaust manifold.
1. Remove the nuts and discard.
2. Remove the LH exhaust manifold.
3. Remove and discard the LH exhaust manifold gaskets.
55. Remove and discard the 8 LH exhaust manifold studs.
56. Remove the bolt and the oil level indicator tube.
Both cylinder heads
57. Clean and inspect the exhaust manifolds. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning And Inspection.
58. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
RH cylinder head
59. NOTICE: 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.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTICE: 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.
NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
Remove the bolts and the RH cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
LH cylinder head
60. NOTICE: 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.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTICE: 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.
NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
Remove the bolts and the LH cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
Both cylinder heads
61. NOTICE: 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.
NOTE: 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 in the following sequence.
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.
62. NOTE: LH shown, RH similar.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to Engine System - General Information Cylinder Head Distortion Cylinder Block Distortion.
