Cylinder Head - Removal

REMOVAL




1. Perform fuel pressure release procedure before attempting any repairs.
2. Disconnect negative cable from battery (1).
3. Raise vehicle on hoist.
4. Drain cooling system.




5. Remove accessory drive belt (5).
6. Remove the vibration damper
7. Disconnect camshaft position sensor (2), and coolant temperature sensor (1) connectors.
8. Remove upper intake manifold




9. Disconnect coils (3), capacitors, and injector connectors (2).
10. Reposition harness out of the way.




11. Disconnect fuel feed line (1)
12. Remove lower intake manifold.
13. Remove cylinder head covers.




14. Remove coolant outlet (3).
15. Remove timing chain cover (4).




16. Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing (2).




17. Remove primary timing chain (7).
18. Remove upper primary timing chain guides (10).




19. Remove camshaft bearing caps gradually in the sequence shown.




20. Remove camshafts (3) & (10) and valvetrain components from cylinder head. Note component locations for re-installation in original locations.
21. For left cylinder head removal:
- Remove fastener securing engine oil dipstick tube to cylinder head. Remove engine oil dipstick tube.
- Remove generator.
22. For right cylinder head removal:
- Remove cylinder head ground strap.
- Disconnect EGR valve electrical connector and remove EGR valve from head.





CAUTION: Ensure cylinder head bolts 1 - 3 are removed before attempting the removal of cylinder head, as damage to cylinder head and/or block may occur.

23. Remove cylinder left head bolts (2) and right head bolts (1) in sequence shown.
24. Remove cylinder head(s).
25. Remove and discard cylinder head gasket.
26. Clean cylinder head and block sealing surfaces.