Removal
Cylinder HeadsSpecial Service Tools:
Removal
1. Disconnect battery ground cable.
2. Drain cooling system and remove fan blade and fan shroud.
3. Relieve fuel system pressure and disconnect fuel lines.
4. Remove air cleaner outlet tube.
5. Remove windshield wiper governor.
6. Release drive belt tensioner and remove drive belt.
7. CAUTION: Do not pull on ignition wire as wires may separate from the connector in the ignition wire boot.
Disconnect ignition wires from spark plugs.
8. Disconnect ignition wires and ignition wire separators from valve cover stud bolts.
9. Disconnect engine control sensor extension wire from both ignition coils and camshaft position sensor (CMP sensor).
10. Remove bolts retaining power steering oil reservoir to the LH ignition coil bracket and position out of the way.
11. Remove three nuts retaining RH ignition coil bracket to engine front cover.
12. Remove LH ignition coil and ignition wires as an assembly.
13. Remove four nuts retaining LH ignition coil bracket to engine front cover.
14. Slide ignition coil brackets and ignition wire and bracket assembly off mounting studs and remove from vehicle.
15. Remove water pump pulley.
16. Disconnect generator wiring harness from junction block, front fender apron and generator (GEN).
17. Remove two bolts retaining generator mounting bracket to intake manifold.
18. Remove two bolts retaining generator to cylinder block and remove generator (GEN).
19. Disconnect and remove positive crankcase ventilation valve (PCV valve) from valve cover.
20. Disconnect 42-pin engine harness connector and 8-pin connector leading to the mass air flow sensor (MAF sensor).
21. Remove nut retaining A/C line to the RH front fender apron.
22. Lift A/C line and feed the fuel charging wiring 42-pin connector under the A/C line. Position fuel charging wiring out of the way.
23. Disconnect the engine control sensor extension wire from the crankshaft position sensor (CKP sensor), A/C clutch and evaporative emission canister purge valves (EVAP canister purge valve).
24. Raise vehicle on hoist.
25. Note: The front lower bolt on the power steering pump will not come all the way out.
Remove bolts retaining power steering pump to cylinder block and engine front cover.
26. Secure the power steering pump out of the way.
27. Remove oil pan and oil pan gasket as outlined.
28. Remove crankshaft pulley bolt and crankshaft pulley retaining washer from crankshaft.
29. Install Crankshaft Damper Remover T58P-6316-D on crankshaft pulley and pull crankshaft pulley from crankshaft.
30. Disconnect the engine control sensor extension wire from the electronic variable orifice sensor and oil pressure sensor.
31. Position engine control sensor extension wire out of the way.
32. Disconnect EGR valve to exhaust manifold tube from RH exhaust manifold.
33. Disconnect three way catalytic converter (TWC) from RH and LH exhaust manifolds.
34. Lower exhaust system and secure to crossmember in positions shown with wire.
Securing Catalytic Converter To Crossmember:
35. Remove bolt retaining starter wiring harness to rear of RH cylinder head.
36. Lower vehicle.
37. Remove bolts and stud bolts retaining RH valve cover to cylinder head and remove valve cover.
38. Disconnect accelerator cable and speed control actuator cable.
39. Remove accelerator cable bracket from intake manifold and position out of the way.
40. Remove bolts and stud bolts retaining LH valve cover to cylinder head and remove valve cover.
41. Disconnect vacuum hose from throttle body adapter vacuum port.
42. Disconnect engine control sensor extension wire from heated oxygen sensors (HO2S).
43. Disconnect heater water hose.
44. Note: Two water outlet connection retaining bolts also retain intake manifold.
Remove two bolts retaining water hose connection to intake manifold and position upper radiator hose and water hose connection out of the way.
45. Remove the remaining nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
46. Remove intake manifold gaskets.
47. Remove seven stud bolts and four bolts retaining engine front cover to engine. Remove engine front cover.
48. Remove timing chains as outlined.
49. Remove 10 bolts retaining LH cylinder head to cylinder block.
50. Note: Cylinder head must not be set on head face. If valves are open damage may occur.
Remove LH cylinder head.
51. Remove the two bolts retaining heater water hose to LH cylinder head.
52. Remove 10 bolts retaining RH cylinder head to cylinder block.
53. Remove RH cylinder head.
54. If cylinder heads are to be replaced or serviced.