Cylinder Head Removal

CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.






NOTICE: Lifters, valve springs, caps, and stem seals can he replaced without removing the cylinder head, using the valve spring tool. The camshaft can be removed through the cylinder head rear plug hole. Front cover assembly, battery and timing chain/gear removal are required.

1. Disconnect cable from negative terminal of battery and remove coolant bottle cap.

NOTICE: The engine's cooling system thermostat will not function correctly once it has been contacted by oil. If oil is found in the cooling system, it must be flushed and the thermostat's cartridge replaced.






2. Drain coolant from radiator and engine. (Engine drain is at right front corner of engine block under thermostat housing).






3. Remove air cleaner assembly and air inlet duct:
a. Disconnect the PCV valve and fresh air hose.
4. Disconnect acceleration cable from TBI throttle lever and bracket from an intake manifold.

IMPORTANT: The intake manifold can be removed from the cylinder head with the engine installed.






5. Remove the following electrical connectors:
a. Water temperature and PCM connectors

IMPORTANT: Long nose pliers are required to remove the coolant temperature connectors.

b. Injector connector
c. Idle air control valve (IAC)
d. Manifold air pressure (MAP)
e. Throttle position switch (TPS)
f. EGR solenoid
g. Spark plug wires
h. 02 sensor
i. A/C compressor






6. Lay harness over onto underhood junction block.






7. Disconnect the following vacuum hoses:
a. Canister purge valve
b. ECIR valve
c. MAP sensor
d. Brake booster vacuum hose at intake manifold or brake booster.
e. TBI assembly






8. Disconnect the upper radiator hose at the cylinder head, and the heater hose at the intake manifold.
a. Disconnect de-aeration hose at connection next to TBI assembly.

CAUTION: CATCH LEAKING FUEL IN AN APPROVED CONTAINER WHEN LOOSENING OR DISCONNECTING FUEL LINES.






9. Disconnect both fuel lines:
a. Fuel pressure can be bled into an approved container using the gage bar kit.
b. Remove attachment bolt that clamps fuel lines to the intake manifold base.
c. Disconnect the fuel supply and return lines going to the TBI assembly. The fuel line can also be disconnected at the quick connector.
d. Remove the lower intake manifold support bracket stud.






10. On a 1992 powertrain with a torque axis mount system, unclip the lower splash shield attachment and place a 1 in. x 1 in. x 2 in. long block of wood between the torque strut and cradle.

IMPORTANT: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.






11. On a 1992 powertrain, remove the three right-hand upper engine torque axis mount-to-front cover nuts and the two mount to midrail bracket nuts, allowing the powertrain to rest on the block or wood.
12. Remove the accessory drive belt and tensioner. It is not necessary to remove the water pump pulley.

IMPORTANT: On 1992 powertrains, the accessory drive belt idler pulley must be removed to allow the front cover to be removed and replaced in the vehicle.

NOTICE: Cover valve train area whenever repairs are not being performed to prevent foreign debris from entering engine.






13. Remove the rocker cover:

IMPORTANT: Inspect the two rocker cover silicone insulators for cracks. Replace isolators if deterioration exist.

a. Disconnect the de-aeration line at cylinder head water outlet and from support bracket.
b. The map sensor can remain attached to the cover with the de-aeration line.






14. Remove the three A/C compressor front bracket bolts (if equipped) attached to cylinder head and block. The rear bracket bolts can be removed from the compressor or bracket attachment to block and head.

IMPORTANT: The rear compressor bracket center hole is slotted for ease of compressor removal and installation.

IMPORTANT: It is not necessary to discharge the A/C system.

a. Tie the compressor assembly to the vehicle front support bar.






15. Remove the three power steering pump bracket attachment bolts (if equipped) and position the pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold.

IMPORTANT: It is not necessary to remove the water pump pulley.

CAUTION: MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.






16. Jack or raise the vehicle on a hoist.
17. Drain engine oil.






18. Remove the right-hand side tire and splash shield.
a. Remove the accessory drive belt tensioner.






19. Remove front crankshaft pulley. Hold pulley with a strap wrench or use a 3/4 in. square x 12 in. long piece of wood wedged between the pulley spoke and rear, lower side of front cover when removing the bolt.
a. Puller jaw slots are cast into pulley for removal with a small three jaw puller, if required.
20. Disconnect front exhaust pipe from exhaust manifold and discard gasket.
a. Remove the three nuts from exhaust manifold.






21. Remove the front cover assembly:
a. Install the crankshaft gear retainer tool to make sure the front crankshaft sprocket is held firmly in place.

IMPORTANT: Install service tool with flat side toward sprocket. Failure to hold the crankshaft timing sprocket in place will cause timing chain guide damage. This tool also aligns the oil pump gerotor during front cover installation.

b. Remove the four front oil pan bolts.
c. Use RTV cutter tool to cut the oil pan seal away from the front cover.
d. Spray the two dowel pin holes in the front cover with penetrating oil to facilitate cover removal off the dowel pins.
e. Remove the front cover bolts.






f. Using a screwdriver, pry the front cover away from the cylinder block, using the pry locations shown.

IMPORTANT: The front cover assembly can be removed from under the hood or through the wheel well.

IMPORTANT: Cover the front of the engine with a shop towel to prevent debris entry into the oil gallery holes and pan.

NOTICE: Positioning crankshaft 90 degree off top dead center (TDC) to make sure pistons Will not contact valves upon assembly.






22. Rotate crankshaft clockwise (viewed from crankshaft accessory belt end) so timing mark on crankshaft sprocket and key way align with main bearing cap split line.






23. Remove timing chain, tensioner, guides, camshaft sprocket, and chain. Use a 21 mm (7/8 in.) wrench to hold the camshaft when removing the sprocket bolt.






24. Remove the TBI assembly and cover the intake manifold opening. Discard gasket.

NOTICE: Only use a six point socket to remove the cylinder head bolts. A 12 point socket will round off the bolt heads.






25. Uniformly loosen and remove the 10 head bolts in several passes, in the sequence shown:






IMPORTANT: Head warpage or cracking could result from removing the bolts out of order or when cylinder head is hot.

NOTICE: Be careful not to damage the aluminum cylinder head and block gasket sealing surfaces when removing the cylinder head or during cleaning.






26. Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks or a bench. If the cylinder head is difficult to lift oft, pry with a screwdriver between the cylinder head and block bosses.