Cylinder Heads Removal
Cylinder HeadsSpecial Tools And Equipment:
Special Tools
Material:
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 bolts and 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 8 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 8 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 wormy 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 8 ignition coils.
48. Remove the bolts and the thermostat housing.
49. Remove the 9 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.
58. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs.
Remove the spark plugs.
59. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
60. Using the special tool, remove the crankshaft front oil seal.
61. Remove the 4 oil pan bolts.
62. 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.
Remove the studs, bolts and the engine front cover.
63. Remove the front cover gaskets, clean and inspect the front cover sealing surfaces.
64. Remove the crankshaft sensor ring from the crankshaft.
65. Install the special tool between the valve spring coils to prevent valve stem seal damage.
66. NOTE: Mark the followers for installation in their original locations.
NOTE: Position the cam lobe away from the camshaft roller follower prior compressing the valve spring.
Using the special tool to compress the valve spring, remove the camshaft roller followers.
67. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
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.
68. Remove the LH and the RH timing chains and the crankshaft sprocket.
69. NOTE: LH shown, RH similar.
Remove the bolts and both timing chain guides.
70. Install the lifting handles on both ends of the cylinder head.
71. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations.
Remove the hydraulic lash adjuster.
72. Remove the nut and the coolant tube.
73. CAUTION: 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.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are torque to yield designed and cannot be reused.
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.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the RH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
74. CAUTION: 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.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are torque to yield designed and cannot be reused.
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.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the LH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
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.
CAUTION: 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.
75. Clean the cylinder head to cylinder block mating surfaces of both cylinder heads and the cylinder block.
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.
76. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat with 0.010 mm (0.0004 inch) from end to end.
NOTE: LH is shown, RH is similar.
Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area or scratches more than 0.0254 mm (0.001 inch).