Cylinder Head Removal
CYLINDER HEAD REPLACEMENT (IN-VEHICLE)TOOLS REQUIRED
- J38122A Crankshaft Pulley Holder
- SA9SOSE Fuel Line Disconnect Set
REMOVAL
1. Disconnect negative battery cable.
2. Remove intake manifold.
3. Remove exhaust manifold flange bolts.
4. Remove coolant reservoir cap.
5. Raise vehicle.
6. Remove exhaust manifold down pipe to catalytic converter bolts.
7. Disconnect exhaust down pipe from exhaust manifold flange studs and secure exhaust pipe to under-carriage.
8. Drain coolant at radiator and at water pump drain plug.
9. Lower vehicle.
10. Relieve fuel system pressure.
11. Remove fuel line bracket bolt.
12. Disconnect fuel lines at quick disconnects using Fuel Line Disconnect Set SA9SOSE.
13. Secure lines away from engine.
14. Disconnect A/C pressure switch electrical connection.
15. Remove crankcase vent hose from camshaft cover.
16. Remove coolant air bleed hose at coolant reservoir and remove from bracket.
17. Disconnect upper radiator hose at cylinder head.
18. Disconnect electrical connections:
1. Ignition Coil
2. Knock Sensor (connector only)
3. Coolant Temperature Sensor
4. Fuel Injector Harness
5. Front 02 Sensor
19. Remove all engine harness bracket fasteners and secure harness away from engine.
20. Remove ignition coil.
21. Remove power steering pump and secure away from engine. Do not remove hydraulic lines.
22. Remove camshaft cover ground strap.
23. Remove camshaft cover bolts and remove cover.
24. Remove upper timing chain guide.
IMPORTANT: The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If it is not, the timing chain may become misaligned and difficult to remove.
25. Remove upper timing chain tensioner.
IMPORTANT: Do not allow any load onto timing chain upon loosening camshaft sprocket bolts.
26. Remove camshaft sprocket bolts using a 24 mm open-end wrench to counter-hold camshaft while loosening bolts. Discard bolts.
27. Attach medium size cable tie to timing chain to prevent chain from falling into oil pan.
28. Remove camshaft sprockets.
29. Remove plug to gain access to fixed timing chain guide bolt.
30. Remove fixed timing chain guide upper bolt only.
31. Remove cylinder head to block bolts using the loosening sequence.
NOTICE: Be careful not to damage the aluminum cylinder head and block gasket sealing surface when removing the cylinder head or during cleaning.
32. Lift the cylinder head from dowels on engine block and place cylinder head on wooden blocks or bench. If cylinder head is difficult to lift off, use a pry bar at designated pry points.
33. Raise vehicle.
34. Remove right front wheel.
35. Remove lower splash shield.
36. Remove accessory drive belt.
37. Remove accessory drive belt tensioner.
38. Remove suction liquid A/C line retaining clips from underneath right side frame rail and position line away to allow clearance to crankshaft pulley bolt.
39. Position crankshaft 60 degrees Before Top-Dead Center (BTDC).
40. Install Crankshaft Pulley Holder J38122A.
IMPORTANT: The crankshaft damper pulley bolt head and washer assembly prevents oil leakage at the center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by hand, use a three jaw puller.
IMPORTANT: Do not pry against cover.
41. Remove and discard crankshaft damper pulley bolt.
42. Remove crankshaft pulley.
43. Remove all front cover bolts except for bolt that is blocked by engine mount bracket.
44. Loosen water pump bolt, do not remove at this time.
45. Lower vehicle.
46. Support engine weight with floor jack under oil pan.
47. Remove right-hand engine mount to bracket bolts.
48. Remove engine mount to body bolts.
49. Remove engine mount from vehicle.
50. Remove engine mount bracket to engine bolts.
51. Remove bracket from vehicle.
52. Lower engine.
53. Remove crankshaft damper pulley and discard bolt.
54. Remove upper front cover bolt (behind engine mount).
55. Raise engine just enough to remove water pump bolt.
56. Remove front cover.
57. Remove adjustable timing chain guide.
58. Remove fixed timing chain guide (lower bolt).