Cylinder Head Gasket [Part 1]

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CYLINDER HEAD GASKET REMOVAL / INSTALLATION - 4.0L

Part 1

Removal Note

Both cylinder heads

1. With the vehicle in neutral, position it on a hoist. See Lifting.

2. Release the fuel system pressure. See Service and Repair.

3. Drain the cooling system. See - Removal and Replacement.

4. Remove the intake manifold. See - Service and Repair.

5. Remove the cooling fan shroud. See - Service and Repair.

6. Remove the accessory drive belt. See - Service and Repair.

7. Remove the LH valve cover. See -- Valve Cover - LH Removal / Installation.

8. Remove the RH valve cover. See -- Valve Cover - RH Removal / Installation.

1. Disconnect the generator electrical connections.

1. Remove the generator mounting bracket and generator as an assembly.
a. Remove the bolt and the drive belt tensioner.

b. Remove the bolts and the generator mounting bracket.

1. Disconnect the engine wiring harness electrical connector and release the harness retainers.

1. Remove the engine wiring harness retainer.

1. Disconnect the crankshaft position (CKP) sensor electrical connector.

1. Remove the wiring anchors and position the wiring aside. Discard the wiring anchors.

1. Disconnect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.

1.
NOTE:The coolant bypass hose will be removed with the thermostat housing.Move the coolant bypass hose clamp off the coolant pump outlet.

1. Remove the bolts and the thermostat housing and coolant bypass hose.

1. Remove the bolt and the wiring harness retainer.

1. Remove the bolts and position the accessory bracket aside.

1. Disconnect the wiring harness casing from the LH cylinder head.

1. Remove the bolt and the oil level indicator tube.

1. Using the spark plug wire remover SST, disconnect the LH spark plug wires from the spark plugs.

1. Disconnect the fuel pressure sensor electrical and vacuum connectors.

1. Remove the fuel injection supply manifold.
a. Remove the four bolts and disconnect the fuel supply tube from the fuel manifold. Position the fuel supply tube aside.

b. Remove the four bolts and the supply manifold and the fuel injectors as an assembly.

1.
NOTE:Mark each of the roller followers to ensure it is installed in its original position during reassembly.Use the valve spring compressor SST to remove the roller followers.

1.
NOTE:The crankshaft timing tool SST must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).Using the crankshaft timing tool SST, set the number 1 piston to TDC.

RH cylinder head

1. Remove the RH fender well splash shield.

1. Remove the RH camshaft tensioner.

2. Remove the RH exhaust manifold. See - Exhaust Manifold Right Hand Removal / Installation.

1. Remove the bolt and the bracket.

1.

CAUTION:The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
NOTE:If necessary, use the torque wrench extension SST to remove camshaft sprocket bolt.

Remove the RH camshaft sprocket bolt.

1. Remove the chain guide bolt.

1.

CAUTION:Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.
NOTE:Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
Remove the RH camshaft sprocket from the cassette.

1. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown, and remove the RH cylinder head.
a. Discard the head gasket.

b. Discard the cylinder head bolts.

2. Clean the gasket mating surfaces.

LH cylinder head

1. Remove the LH exhaust manifold. See Exhaust Manifold Left Hand Removal / Installation.

1. Remove the bolt and the ground strap.

1. Remove the engine wiring harness pin-type retainer.

1. Remove the LH hydraulic chain tensioner.

1. Remove the camshaft sprocket bolt.

1. Remove the chain guide bolt.

1. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown and remove the LH cylinder head.
a. Discard the head gaskets.

b. Discard the cylinder head bolts.

2. Clean the gasket mating surfaces.

Continued in Part 2 Cylinder Head Gasket [Part 2]