Removal

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

Special Tools:

1. Disconnect the battery ground cable.
2. Perform fuel pressure release procedure.

WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN. THIS PRESSURE MUST BE RELIEVED BEFORE DISCONNECTING ANY FUEL LINES OR FUEL SYSTEM COMPONENTS.

3. Remove the timing belt.





4. Remove the engine air cleaner intake tube and the outlet half of the engine air cleaner.
5. Remove the vacuum hoses at the (1) exhaust gas recirculation (EGR) valve, the (2) positive crankcase ventilation (PCV) valve, the (3) throttle body, the (4) fuel pressure sensor, and the (5) intake manifold.





6. Disconnect the (1) speed control cable and the (2) accelerator cable from the throttle control lever.





7. Remove the speed control cable bracket bolts.





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 (H02S) electrical connector mounted on the cooling fan shroud.





11. Use Disconnect Tool and disconnect the fuel supply line from the fuel injection supply manifold.





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





13. Pivot the generator forward.
1 Loosen the lower bolt.
2 Remove the upper bolt.
3 Pivot the generator forward.





14. Remove the bolt from the intake manifold.





15. Disconnect the EGR tube from the EGR valve.





16. Disconnect the EGR tube from the exhaust manifold.





17. Remove the (A) five nuts and remove the (B) exhaust manifold shield.





18. Remove the nuts.
19. Raise and support the vehicle.
20. Drain the engine coolant.





21. Remove the (A) six bolts and remove the (B) RH splash shield assembly.





22. Remove the oil level indicator tube from the cylinder block.





23. Disconnect the A/C compressor electrical connector.
24. Remove the A/C compressor.





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





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





28. Remove the bolt.





29. Remove the bolts, the valve cover and the gasket.





30. Disconnect the upper radiator hose from the thermostat housing water hose connection.





31. Disconnect the heater hose from the thermostat housing.





32. Remove the ten cylinder head bolts, the cylinder head, and the head gasket. Discard the gasket and bolts.

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