Removal

Cylinder Heads





Special Tool(s)





Material

1. Remove the engine.





2. Remove the flexplate.





3. Remove the engine/transmission spacer plate.





4. Mount the engine on a work stand.





5. Remove the special tools.





6. Remove the bolts and the RH engine mount.





7. NOTE: RH shown, LH similar.

Remove the drain plugs from the engine block.
Allow the coolant to completely drain.
^ Install the drain plugs when finished.





8. Disconnect the Positive Crankcase Ventilation (PCV) tube.





9. Disconnect the vacuum hoses and the PCV valve coolant hoses.





10. Remove the bolt and the bracket.





11. Disconnect the exhaust gas recirculation (EGR) system module tube from the EGR system module.





12. Disconnect the EGR system module tube from the exhaust manifold.





13. Disconnect the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor electrical connectors.





14. Remove the upper intake manifold assembly bolts in the sequence shown and remove the intake manifold assembly.





15. Disconnect the electrical connector, generator cable and the pin-type harness retainer.





16. Remove the bolts and the generator support bracket.





17. Disconnect the Engine Coolant Temperature (ECT) sensors.





18. Remove the crossover tube.





19. Remove the bolts and the generator.





20. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.





21. Separate the fuel charging wiring from the fuel injection supply manifold studs in three places.





22. Disconnect the eight fuel injector electrical connectors.





23. Remove the eight bolts and two studs in the sequence shown and raise the lower intake manifold slightly.





24. Disconnect the fuel charging wiring harness from the rear of the lower intake manifold and remove the manifold.
25. Remove the intake manifold gaskets.

26. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tool will cause scratches and gouges which make leak paths.

Clean the sealing surfaces.





27. Remove the LH coil cover.





28. Remove the RH coil cover.





29. Disconnect the LH ignition coil electrical connectors.





30. Disconnect the RH ignition coil electrical connectors.





31. Remove the eight ignition coils.





32. Disconnect the knock (KS) sensor jumper harness from the fuel charging harness.





33. Remove the coolant pump pulley.
1 Remove the bolts.
2 Remove the coolant pump pulley.





34. Remove the bolt.





35. Using the special tool, remove the crankshaft pulley.





36. Using the special tool, remove the crankshaft front seal.





37. Remove the belt idler pulleys.





38. Disconnect the Camshaft Position (CMP) sensors and the engine wiring harness retainers.





39. Disconnect the oil pressure sensor electrical connector.





40. NOTE: LH shown, RH similar.

Disconnect and remove the LH and RH radio capacitors.
^ Disconnect the electrical connectors.
^ Remove the nuts and capacitors.





41. Disconnect the retainers and remove the fuel charging wiring harness.





42. NOTE: LH shown, RH similar.

Remove the eight spark plugs.





43. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the LH valve cover.
^ Remove and discard the gasket, clean and inspect the sealing surfaces.





44. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remover the RH valve cover.
^ Remove and discard the gasket, clean and inspect the sealing surfaces.





45. Remove the LH exhaust manifold.
1 Remove the 16 nuts.
2 Remove the exhaust manifold.
3 Remove the exhaust manifold gasket.





46. Remove the oil level indicator tube.





47. Remove the RH exhaust manifold.
1 Remove the RH exhaust manifold nuts.
2 Remove the RH exhaust manifold.
3 Remove the RH exhaust manifold gasket and discard.





48. Remove the coolant bypass tube.
1 Remove the retaining nut.
2 Remove the ground strap.
3 Remove the coolant bypass tube.





49. Remove the nut and position the wiring harness bracket aside.
50. Clean and inspect the exhaust manifolds.





51. Remove the four bolts.

Part 1 Of 2:

Part 2 Of 2:

52. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean and inspect the mating surfaces.

NOTE: Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Remove the bolts and the engine front cover.





53. Remove the Crankshaft Position (CKP) sensor pulse wheel.

54. CAUTION: Mark the roller follower positions. Reused followers must be installed in their original locations.

Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.





55. Using the special tool, compress the intake valve spring and remove the roller follower.





56. Using the special tool, compress the exhaust valve spring and remove the roller follower.
57. Repeat the above three steps to remove all the necessary roller followers. Inspect the roller followers and camshafts.





58. Remove the bolts and the RH and LH timing chain tensioners.





59. Remove the RH and LH timing chain tensioner arms.





60. Remove the RH and the LH timing chains and crankshaft sprocket.





61. Remove the RH and LH timing chain guides.





62. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.

Remove the hydraulic lash adjusters.





63. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the bolts and the RH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.





64. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.

Remove the bolts and the LH cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.

65. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3 Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4 Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surface is normal.

66. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 inch) per foot of tool length.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).