Cylinder Head - Removal
Cylinder Head
All cylinder heads
1. Remove the engine. For additional information, refer to Engine Engine - Removal in the Removal.
2. Remove the bolts and the flexplate or flywheel.
3. NOTICE: Do not use the oil pan to support the engine or oil pan and oil pan gasket damage may occur.
Lower and support the engine assembly on wood blocks.
4. Remove the Engine Lifting Bracket.
5. Install the engine assembly onto a suitable engine stand.
6. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support insulator bracket.
- Discard the 3 engine support insulator bracket bolts.
7. NOTE: LH shown, RH similar.
If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
8. NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.
Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the engine cooling fan from the coolant pump pulley.
9. Disconnect the Camshaft Position (CMP) sensor electrical connector.
10. Remove the nut and the RH radio ignition interference capacitor.
11. Disconnect the 10 ignition coil electrical connectors.
12. Remove the 10 bolts and the 10 ignition coils.
- Remove the ignition coil by using a twisting motion while pulling up on the ignition coil.
13. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
14. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
15. Remove the nut and the LH radio ignition interference capacitor.
16. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
17. Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
18. Remove the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.
19. NOTICE: 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.
NOTE: The bolts are part of the valve cover and should not be removed.
Loosen the 16 fasteners in the sequence shown and remove the RH valve cover and gasket.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
20. NOTICE: 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.
NOTE: The bolts are part of the valve cover and should not be removed.
Loosen the 17 fasteners in the sequence shown and remove the LH valve cover and gasket.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
21. Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.
22. Remove the 3 bolts and the accessory drive belt tensioner.
23. Remove the crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.
24. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
25. Using the Crankshaft Front Seal Remover, remove and discard the crankshaft front seal.
26. Remove the front 4 oil pan bolts.
27. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Remove the 15 fasteners.
28. Remove the engine front cover from the cylinder block.
29. NOTICE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
Loosen and back off the RH camshaft sprocket bolt one full turn.
30. NOTICE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
Loosen the LH camshaft sprocket bolt.
31. NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
Using the sequence shown, remove the 6 bolts, then the 3 balance shaft bearing caps and the balance shaft.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Position the crankshaft keyway at the 12 o'clock position.
34. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
35. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.
Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
36. NOTICE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
37. NOTICE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.
Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.
38. NOTICE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the Valve Spring Compressor, remove the 4 designated camshaft roller followers in the previous step from the LH cylinder head.
39. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
40. NOTICE: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
41. NOTICE: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
42. Remove the LH and RH timing chain and the crankshaft sprockets.
- Remove the RH timing chain from the camshaft sprocket.
- Remove the RH timing chain from the crankshaft sprocket.
- Remove the LH timing chain from the camshaft sprocket.
- Remove the LH timing chain and the crankshaft sprocket.
43. Remove the 4 bolts and the timing chain guides.
44. Remove the bolts and the RH and LH camshaft sprockets.
45. Remove the balance shaft drive gear from the LH camshaft.
46. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the RH camshaft front bearing cap.
47. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
Remove the 10 remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
48. Clean and inspect the RH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
49. Remove the RH camshaft.
50. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the LH camshaft front bearing cap.
51. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
Remove the 10 remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
52. Clean and inspect the LH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
53. Remove the LH camshaft.
54. NOTICE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
Remove all of the remaining roller followers from the cylinder heads.
LH cylinder head
55. NOTICE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
Remove the hydraulic lash adjusters from the LH cylinder head.
56. Install the Cylinder Head Remover/Installer onto the LH cylinder head.
57. Remove the 3 bolts and the exhaust manifold heat shield.
58. Remove the 10 nuts and the LH exhaust manifold.
- Discard the 2 gaskets and the 10 nuts.
- Inspect the exhaust manifold. For additional information, refer to Engine.
59. Remove and discard the 10 exhaust manifold-to-cylinder head studs.
RH cylinder head
60. NOTICE: If the components are to be reinstalled, they must be installed in the same positions or engine damage may occur. Mark the components for installation into their original locations.
Remove the hydraulic lash adjusters from the RH cylinder head.
61. Install the Cylinder Head Remover/Installer onto the RH cylinder head.
62. Remove the heater coolant tube stud bolt.
63. Remove the 2 bolts and the exhaust manifold heat shield.
64. Remove the 10 nuts and the RH exhaust manifold.
- Discard the 2 gaskets and the 10 nuts.
- Inspect the exhaust manifold. For additional information, refer to Engine.
65. Remove and discard the 10 exhaust manifold-to-cylinder head studs.
All cylinder heads
66. NOTICE: 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.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine or engine damage may occur.
NOTICE: The cylinder head bolts must be discarded and new bolts must be installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.
NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface, or cylinder head damage may occur.
NOTE: RH shown, LH similar.
Remove the 12 bolts and the cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
67. NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTICE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep or engine damage may occur.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
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 surfaces is normal.
68. NOTE: LH shown, RH similar.
Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
