Cylinder Head Removal
Cylinder Head Replacement
^ EN-48464 Lower Timing Gear Tensioner Holding Tool
^ EN 46547 Flywheel Holding Tool
^ J 44221 Camshaft Holding Tool
^ J 45059 Angle Meter
Removal Procedure
1. Bleed the fuel pressure.
2. Remove the air induction assembly from the vehicle.
3. Remove the battery from the vehicle.
4. Disconnect the Fuel/EVAP lines from the intake manifold and move aside. Includes fuel line removal from fuel rail.
5. Remove the bolt holding the oil indicator tube to the intake manifold and move the oil indicator tube aside. Do not remove.
6. Lift the Vehicle.
7. Remove the engine shield from the vehicle.
8. Remove the oil pan skid plate from the vehicle.
9. Remove the drive belt.
10. Drain the engine oil.
11. Drain the engine coolant.
12. Remove the left front wheelhouse panel.
13. Remove the fir tree wiring harness connectors from the engine wring harness bracket from the left front wheelhouse opening.
14. From the left front wheelhouse, remove the engine wiring harness bracket from the engine and set aside.
15. Remove the intake manifold bolts from the wheelhouse access. The bolts stay with intake manifold.
On two-wheel drive vehicles, the intake manifold bolts are removed from the top of the engine, not through the left front wheelhouse panel.
16. Lower the vehicle.
17. Remove the positive crankcase ventilation (PCV) pipes (2, 6) from the cam cover and remove the intake manifold from the vehicle.
18. Remove the generator output BAT terminal nut.
19. Remove the generator lead from the generator.
20. Disconnect the generator electrical connector.
Important: The generator does not have to be removed from the vehicle. On a two-wheel drive vehicle, the generator must be removed from the vehicle.
21. Remove the generator bolts and set the generator aside.
22. Disconnect the A/C pipe clamp from the engine lift hook bracket.
23. Remove the engine lift hook bracket bolts and bracket from the vehicle.
24. Remove the bolts holding the windshield washer solvent container and coolant recovery reservoir to the right inner fender. Move aside to gain access to the engine wiring harness to the powertrain control module (PCM).
25. Disconnect the following cross-vehicle engine wiring harness connectors:
^ PCM
^ Engine coolant temperature sensor
^ Manifold absolute pressure (MAP) sensor
^ Ignition coils
^ Harness clamps at power steering pump
^ Wiring harness fastener at right front inner fender
^ Throttle body
^ Camshaft sensors
^ Exhaust camshaft actuator
^ Fuel injectors
^ HO2S 1
^ Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
26. If equipped, remove the secondary air injection (AIR) injection pipe block-off plate bolts from the cylinder head.
27. If equipped, remove the AIR injection pipe block-off plate.
28. Remove the bolts from the exhaust manifold heat shield.
29. Remove the exhaust manifold heat shield.
30. Remove the exhaust manifold bolts.
31. Move the exhaust manifold back and away from the cylinder head.
32. Remove the bolts to all ignition coil assemblies and remove all ignition coil assemblies from the cam cover.
33. Remove all the spark plugs from the cylinder head.
34. Remove the cam cover from the cylinder head.
35. Remove the inlet radiator hose and clamp from the cylinder head.
36. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.
37. Perform one of the following methods for the service timing procedure.
38. First Method--Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder.
39. First Method (continued)--The TDC indicator tool graduation marks on the shaft should note top of the piston stroke.
40. First Method (continued)--When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.
41. Second Method--Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gage should not slide under the straight edge (1).
42. Once TDC is located for the number 1 cylinder using above methods, raise the vehicle and lock the flywheel with the EN 46547.
43. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.
44. Lower the vehicle.
Caution: The camshaft holding tools must be installed on the camshafts to prevent camshaft rotation. When performing service to the valve train and/or timing components, valve spring pressure can cause the camshafts to rotate unexpectedly and can cause personal injury.
Important: If the timing is correct (TDC compression stroke number 1 cylinder), the camshaft flats will be in the up position.
45. Install J 44221 to the back of the camshafts.
46. Remove the upper timing chain guide to the cylinder head.
47. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.
Notice: DO NOT use excessive force to seat the wedge tool. If excessive force is used, you may damage the timing chain tensioner or break the front cover bolt requiring complete disassembly of the front engine.
48. Install EN-48464. It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.
49. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain. Front cover removed for illustration purposes.
50. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer.
51. Once the tool is correctly installed, unscrew the handle and remove the handle.
Important:
^ Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. It is critical that the crankshaft does not move and is held at TDC when the intake and exhaust camshaft sprocket bolts are removed.
^ If the crankshaft is not held in place, the wedge tool could be dislodged. If the crankshaft moves, or if the tool is not seated properly allowing the timing chain tensioner to extend, the repair will have to be completed by removing the front cover to release the timing chain tensioner.
52. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
53. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
54. Remove upper timing chain tensioner shoe bolt.
55. Remove upper timing chain tensioner guide bolt.
56. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.
57. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts. The illustration shows the exhaust camshaft sprocket already removed.
58. Remove the sprockets from the chain, tie a piece of mechanic's wire on the timing chain and let it drop.
59. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.
60. Remove the cylinder head bolts. Discard the bolts.
61. Remove the cylinder head.
62. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
63. Remove the cylinder head gasket.
Discard the gasket.
64. Remove all remaining gasket material from the engine block.
65. Inspect the cylinder head gasket mating surface on the engine block.
66. Clean and inspect the cylinder head.
67. Disassemble the cylinder head if necessary.