Part 2
Cylinder Head Removal (Part 2 of 2)
41. Remove the bolts and position the fuel charging wiring out of the way.
42. Remove the bolts from the isolation valve.
All Engines
43. Remove the bolts and the coolant outlet adapter.
44. Remove the thermostat.
45. Remove the bolts and the intake manifold.
46. Remove the intake manifold gaskets.
47. 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.
Clean the sealing surfaces.
48. Remove the power steering bracket nut.
49. Disconnect the power steering high pressure tube.
50. Remove the power steering pump.
51. Remove the coolant bypass tube.
- Remove the retaining nut.
- Remove the ground strap.
- Remove the coolant bypass tube.
52. Remove the studs and bolts, and remove the valve cover.
- Clean the mating surface, and if necessary, install new gaskets.
53. Remove the studs and bolts and remove the right valve cover. Clean the mating surface, and if necessary, install new gaskets.
54. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Remove the spark plugs.
55. Position the lobe of the camshaft up.
56. Install the special tool between the valve spring coils to prevent valve stem seal damage.
57. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
Use the special tool to compress the valve springs and remove the camshaft roller followers.
58. Remove the bolt and the belt idler pulley.
59. Remove the coolant pump pulley.
60. Remove the crankshaft pulley bolt.
61. Using the special tool, remove the crankshaft pulley.
62. Using the special tool, remove the crankshaft front oil seal.
63. Remove the front four oil pan bolts.
64. Remove the fasteners.
65. Remove the engine front cover from the cylinder block.
- Clean the sealing surfaces and discard the gaskets.
66. Remove the crankshaft sensor ring.
67. Position the crankshaft with the keyway at the 12 o'clock position.
68. Remove the timing chain tensioning system from both timing chains.
- Remove the bolts.
- Remove the timing chain tensioners.
- Remove the timing chain tensioner arms.
69. Remove the LH and RH timing chains and the crankshaft sprocket.
- Remove the RH timing chain from the camshaft sprocket.
- Remove the RH timing chain from the crankshaft sprocket.
- Repeat for the LH timing chain and crankshaft sprocket.
70. Remove both timing chain guides.
- Remove the bolts.
- Remove the LH timing chain guide.
- Remove the bolts.
- Remove the RH timing chain guide.
RH Cylinder Head
71. Remove the RH exhaust manifold.
- Remove the nuts.
- Remove the RH exhaust manifold.
- Remove and discard the RH exhaust manifold gasket.
LH Cylinder Head
72. Remove the LH exhaust manifold.
- Remove the nuts.
- Remove the LH exhaust manifold.
- Remove and discard the LH exhaust manifold gasket.
73. Remove the bolt and the oil level indicator tube.
Both Cylinder Heads
74. Clean and inspect the exhaust manifolds.
75. Install the special tool on both ends of the cylinder head.
76. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
RH Cylinder Head
77. 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 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.
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.
LH Cylinder Head
78 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 tighten4o-yield designed and cannot be reused.
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 that 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 LH cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts
Both Cylinder Heads
79. 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 that 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 the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
- Remove any large deposits of silicone or gasket material with a plastic scraper.
- Apply silicone gasket remover, following package directions, and allow to set for several minutes.
- 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.
- 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.
80. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) 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 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).