Part 1 of 2

Cylinder Head








Special Tool(s)





Material

Removal

Both sides
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine cooling system.
3. Remove the roller followers.
4. Remove the accessory drive belt tensioner.

RH side





5. Disconnect the generator electrical connections and disconnect the pushpin.





6. Remove the generator mounting bracket assembly.





7. Remove the heater hose from the thermostat housing.





8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





9. Disconnect the upper radiator hose.





10. Position the coolant bypass hose clamp aside.





11. Remove the bolts and the thermostat housing.





12. Remove the engine wiring harness bolts and position the engine wiring harness aside.





13. Remove the engine around strap.

LH side





14. Disconnect the radio ignition interference capacitor electrical connector.





15. Remove the bolts.





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





17. Remove the bolts and the coil bracket.





18. Remove the oil level indicator tube.

Both sides





19. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

Disconnect all of the spark plug wires from the spark plugs.





20. Remove the engine noise shield.





21. NOTE: LH side shown, RH side similar.

Remove the four catalytic converter-to-manifold nuts.





22. Remove both of the exhaust manifolds and gaskets.
^ Discard the gaskets and the retaining nuts.

RH side





23. Remove the RH side hydraulic chain tensioner.





24. Install the special tools.





25. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.





26. Remove the RH side cassette bolt.





27. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

LH side





28. Remove the LH side hydraulic chain tensioner.





29. Install the special tools. Tighten the top clamp bolts to 10 Nm (89 inch lbs.).





30. Remove the LH side camshaft sprocket bolt.





31. Remove the LH side cassette bolt.





32. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

Both sides





33. CAUTION: To avoid damage to the timing chain cassette an assistant will be required to help lift the cylinder head from the vehicle.

CAUTION: On the RH side, when lifting the cylinder head be careful to avoid contacting the A/C tube.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the cylinder heads.
^ Remove the cylinder head bolts in the sequence shown. Discard all bolts.
^ Remove and discard the head gasket.

34. 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.

Clean and inspect the mating surfaces.
35. Inspect the cylinder head and the cylinder block for flatness.