Removal

1. Disconnect the battery ground cable (14301). Refer to Starting and Charging.

WARNING:
FUEL UNDER PRESSURE
Fuel in the fuel system remains under HIGH PRESSURE for long periods of time, even when the engine is not RUNNING. To avoid injury or fire, release the fuel pressure from the fuel system before disconnecting any fuel line.

Fire Hazard
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury

2. Relieve the fuel system pressure. Refer to Powertrain Management.
3. Remove the timing belt.
4. Remove the air cleaner intake tube (9C675) and the outlet half of the engine air cleaner. Refer to Powertrain Management.





5. Remove the vacuum hoses at the (A) exhaust gas recirculation (EGR) valve, the (B) positive crankcase ventilation (PCV) valve, the (C) throttle body, the (D) fuel pressure regulator, and the-(E) intake manifold.





6. Disconnect the (A) speed control cable, the (B) accelerator cable, and the (C) throttle valve control actuating cable from the throttle control lever.





7. Remove the two speed control cable bracket bolts and position the bracket and cables aside.





8. Disconnect the two fuel charging wiring electrical connectors.





9. Disconnect the crankshaft position (CKP) sensor electrical connector.





10. Disconnect the upstream heated oxygen sensor (HO2S) electrical connector mounted on the cooling fan shroud.
11. Use Disconnect Tool D87L-9280-A/B or equivalent and disconnect the fuel lines from the fuel injection supply manifold.





12. Remove the (A) three bolts and position the (B) power steering pressure hose (3A719) and bracket aside.





13. Loosen the lower generator (GEN) bolt (1).
14. Remove the upper bolt (2) and pivot the generator (3) forward.
15. Remove the oil level indicator tube bracket bolt from the intake manifold.





16. Disconnect the EGR tube from the EGR valve.





17. Disconnect the EGR tube from the exhaust manifold (9430).
18. Remove the five nuts and remove the exhaust manifold shield (9A462).





19. Remove the four exhaust manifold-to-three way catalytic converter (TWC) nuts.
20. Raise and support the vehicle.
21. Drain the cooling system.
22. Remove the (A) six bolts and remove the (B) RH splash shield assembly.
23. Remove the oil level indicator tube from the cylinder block.
24. Disconnect the electrical connector from the A/C compressor.

NOTE: Support the A/C compressor (19703) with wire.

25. Remove the four bolts and position the A/C compressor aside.





26. Loosen the lower four bolts and one nut securing the front engine accessory drive bracket approximately four turns (3/8 in). Do not remove.
27. Lower the vehicle.

NOTE: Remove the uppermost front engine accessory drive bracket to cylinder head bolt only.





28. Remove the uppermost front engine accessory drive bracket to cylinder head bolt.





29. Remove the A/C line bracket to front engine accessory drive bracket bolt.
30. Remove the three bolts and remove the valve cover (6582).
31. Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection.
32. Disconnect the heater hose from the thermostat housing.

CAUTION:
Aluminum Components
Do not work on aluminum engine components until the engine is cold.

Injury Hazard
Do not attempt to remove the cylinder head assembly without assistance. REMOVAL of the cylinder head assembly requires two persons.

NOTE: Maintain a balanced pressure when removing the cylinder head bolts.

33. Remove the ten cylinder head bolts, the cylinder head (6049), and the head gasket (6051). Discard the gasket and bolts.