Cylinder Head Removal

Cylinder Head Replacement

^ Tools Required
- J 38122-A Crankshaft Pulley Holder
- J 43405 Engine Support Fixture Adapter
- J 44811 Accessory Belt Tensioner Unloader
- J 45122 Engine Support Adapter
- SA9105E Engine Three Bar Fixture
- SA9127E Gage Bar Set
- J45027 Tensioner Tool

Removal Procedure





1. Disconnect the negative battery cable.
2. Disconnect the Intake Air Temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove outlet resonator/duct assembly.
8. Remove the air cleaner assembly hold-down bolt.
9. Remove the air cleaner assembly.





10. Remove the ignition module bolts.
11. Remove the ignition module assembly.





12. Disconnect ECM electrical connector and ground at ECM.
13. Remove oil level indicator bolt to manifold.
14. Disconnect the electrical connector at the throttle body.
15. Disconnect the electrical connector at the fuel injector harness and the attachment at bottom of the intake manifold.
16. Disconnect the electrical connector at purge solenoid and MAP sensor.
17. Disconnect the vacuum hose at the brake booster.





18. Disconnect the coolant pipe bracket bolts to front of cylinder head.





19. Disconnect the degas hose at clamp at the cylinder head and uncap from the fuel rail. Position away from the cam cover assembly.
20. Disconnect ground strap at rear of the cam cover assembly.





21. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
22. Disconnect the SA9127E after pressure has been relieved.





23. Disconnect the fuel rail bracket and bolt at the rear cam cover.





Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.

Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.

24. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at the fuel rail.





25. Position the fuel line away from the cam cover assembly.
26. Remove the cam cover assembly bolts.
27. Remove the cam cover assembly.





Notice: To avoid valve piston contact, No. 1 cylinder piston must be positioned at approximately 60° Before-Top Dead Center (BTDC). Pistons are properly positioned when the diamond shaped hole on the intake camshaft sprocket is located at 12 o'clock.

Important: To rotate camshafts, use a 24 mm open-end wrench on camshaft flats. Camshafts should be rotated in a clockwise direction only, facing camshaft sprockets from passenger side of vehicle.

28. Locate the No.1 piston to approximately 60° before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.





29. Remove upper timing chain guide.





Important: The timing chain tensioner must be removed to unload chain tension before timing chain is removed. If it is not removed, the timing chain may bind and be difficult to remove.

30. Remove the timing chain tensioner.





31. Remove the fixed timing chain guide access plug.
32. Using a magnetic socket, remove the upper fixed guide bolt.





33. Install SA9105E set up for SUV application. Also, use J 45122 with long hooks from J 43405. Refer to Engine Support Fixture.





34. Remove the right-hand engine mount-to-bracket bolts.
35. Remove the right-hand mount assembly nuts.
36. Remove the right-hand engine mount assembly.





37. Remove the right-hand mount bracket.
38. Remove the right-hand engine mount bracket.
39. Raise the vehicle on hoist.
40. Remove the right wheel and splash shield.
41. Remove J 44811.
42. Remove the accessory drive belt.
43. Remove the tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.





44. Remove the tensioner assembly.





45. Install J 33122-A.





Important: The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a threw-jay puller.

46. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.





Notice: To avoid damage to the front cover assembly, do not pry against the cover.

47. Remove the front cover assembly bolts.
48. Remove the lower water pump assembly bolt.
49. Remove the front cover assembly and gasket.





50. Remove the adjustable guide bolt.





51. Remove the lower fixed guide bolt.
52. Remove the fixed guide.





53. Drain the coolant system.





54. Remove the exhaust manifold pipe to the manifold nuts.
55. Disconnect the electrical connectors at the front and rear oxygen sensors.
56. Remove down pipe to intermediate pipe nuts.
57. Remove down pipe assembly.
58. Lower the vehicle.





59. Remove the upper radiator hose from cylinder head.





Notice: The camshaft sprocket bolts are not reusable, it is a Torque-To-Yield (TTY) bolt, and must be discarded to prevent premature failure.

60. Use a 24 mm wrench to hold the camshaft assembly while removing the exhaust sprocket bolt. Discard the bolt.
61. Remove the exhaust sprocket.





62. Remove the adjustable guide through the top of the cylinder head.





63. Use a 24 mm wrench to hold the camshaft assembly while removing the intake sprocket bolt. Discard the bolt.
64. Remove the intake sprocket.
65. Remove the timing chain assembly through top of cylinder head.
66. Remove the timing chain drive sprocket from the crankshaft.





67. Remove the timing chain oiling nozzle and remove any debris from hole in block.





Important: Replace timing chain guides if wear exceeds 1.12 mm (0.045 inch).

68. Inspect timing chain guide for wear.
69. Inspect the timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on the chain.





Caution: Do not raise the vehicle without the right hand mount or the engine support fixture attached. Bodily harm or engine mount damage may occur.

70. Install floor jack with block of wood and support the engine at the center of the oil pan.
71. Remove engine three bar engine support fixture to allow cylinder head to be removed.





72. Remove cylinder head bolts using loosening sequence.
73. With assistance, remove the cylinder head from block with the exhaust and intake manifold attached.