Part 1 of 2
Cylinder Heads
Special Tool(s)
Material
1. Remove the engine.
2. Remove the bolts and the flexplate.
3. Remove the spacer plate.
4. Install the engine on a suitable engine stand.
5. Rotate the belt tensioner and remove the accessory drive belt.
6. Disconnect the oil pressure sensor electrical connector.
7. Remove the nuts and position the wiring harness bracket aside.
8. Remove the power steering hose support bracket.
9. Disconnect the return and pressure hoses from the power steering pump.
10. Remove the bolts and the power steering pump.
11. Remove the nut and position the radio capacitor and ground cable aside.
12. Remove the power steering reservoir and bracket from the stud.
13. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
14. Disconnect the wiring harness retainers.
15. Detach the wiring harness retainer from the A/C tube.
16. Remove the bolt and position the wiring harness aside.
17. Remove the crankcase air inlet tube.
18. Remove the nut and the upper radiator hose bracket and position the radio interference capacitor aside.
19. Remove the bolts and the idler pulleys.
20. Disconnect the generator electrical connectors and pin-type retainer.
21. Remove the bolts and the bracket.
22. Remove the bolts and the generator.
23. Disconnect the electrical connector and remove the bolt and the camshaft position (CMP) sensor.
24. Remove the coolant pump pulley.
1. Remove the bolts.
2. Remove the coolant pump pulley.
25. Remove the exhaust gas recirculation (EGR) system module-to-manifold tube.
26. Remove the RH exhaust manifold heat shield.
27. Remove the RH exhaust manifold.
1. Remove the eight nuts.
2. Remove the RH exhaust manifold.
3. Remove and discard the RH exhaust manifold gasket.
28. Remove the LH exhaust manifold heat shield.
29. Remove the LH exhaust manifold.
1. Remove the eight nuts.
2. Remove the LH exhaust manifold.
3. Remove and discard the LH exhaust manifold gasket.
30. Remove the bolt and the oil level indicator tube.
31. Clean and inspect the exhaust manifolds.
32. Remove the bolt and the brake booster vacuum hose.
33. Disconnect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
34. Remove the positive crankcase ventilation (PCV) tube and disconnect the vacuum tube from the throttle body adapter.
35. Disconnect the EGR system module and fuel pressure sensor vacuum fittings.
^ Remove the vacuum harness from the engine.
36. Disconnect the EGR system module and fuel pressure sensor electrical connectors.
37. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
38. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
39. Disconnect the coolant hoses.
40. Disconnect the coolant hose.
41. Remove the bolts and the electronic throttle body and adapter.
42. Disconnect the RH fuel injector, coil and ground electrical connectors, and the wiring harness retainers.
43. Disconnect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
44. Disconnect the wiring harness retainers.
45. Disconnect the ground wire.
46. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.
47. NOTE: LH is shown, RH is similar.
Remove the bolts and all eight ignition coils.
48. Remove the bolts and the thermostat housing.
49. Remove the nine bolts and the intake manifold.
50. Remove the intake manifold gaskets.
51. 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.
Clean the sealing surfaces.
52. Remove the bolts and the LH engine mount.
53. Remove the bolts and the RH engine mount.
54. Remove the RH cylinder block drain plug.
^ Reinstall the drain plug after draining the coolant.
55. Remove the LH cylinder block drain plug.
^ Reinstall the drain plug after draining the coolant.
56. 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.
NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
Remove the LH valve cover.
^ Clean and inspect the mating surfaces and if necessary, install new gaskets.
57. 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.
NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
Remove the RH valve cover.
^ Clean and inspect the mating surfaces and if necessary, install new gaskets.