Removal

Cylinder Head

Special Tool(s):

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. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.





RH side
5. Remove the bolts and position the heater hose tube bracket aside.





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





7. Remove the bolt and the accessory drive belt tensioner.





8. Remove the generator mounting bracket assembly.





9. Remove the heater hose from the thermostat housing.





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





11. Disconnect the upper radiator hose.





12. Position the coolant bypass hose clamp aside.





13. Remove the bolts and the thermostat housing.





14. Remove the bolt and position the engine wiring harness aside.





15. Remove the engine ground strap.





16. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire.

NOTE: Spark plug wires must be connected to the correct spark plug. Mark the spark plug wires for installation reference.

With a twisting motion, use the special tool to pull the spark plug wires from the RH spark plugs.





17. Remove the catalytic converter-to-RH exhaust manifold nuts.





18. Remove the nuts, the RH exhaust manifold and the gasket.
^ Discard the nuts and the gasket.

19. Remove and discard the 6 RH exhaust manifold studs.





20. Remove the RH side hydraulic chain tensioner.





21. NOTE: Late build vehicles shown, early build vehicles similar.

Install the special tools.
^ Tighten to 10 Nm (89 inch lbs.).





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





23. NOTE: Late build vehicles shown, early build vehicles similar.

Remove the RH side cassette bolt.





24. 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
25. Disconnect the radio ignition interference capacitor electrical connector.





26. Remove the bolts.





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





28. Remove the bolts and the coil bracket.





29. Remove the oil level indicator tube.





30. Remove the catalytic converter-to-LH exhaust manifold nuts.





31. Remove the nuts, the LH exhaust manifold and the gasket.
^ Discard the nuts and the gasket.

32. Remove and discard the 6 LH exhaust manifold studs.





33. Remove the LH side hydraulic chain tensioner.





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





35. Remove the LH side camshaft sprocket bolt.





36. Remove the LH side cassette bolt.





37. 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

38. 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.

NOTE: Late build vehicles shown, early build vehicles similar.

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

39. 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.
40. Inspect the cylinder head and the cylinder block for flatness.