Part 1

Cylinder Head








Removal (Steps 1-33)

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Both cylinder heads
1. Remove the engine from the vehicle.
2. Remove the 8 flywheel bolts.

3. CAUTION: The flywheel is a press fit on the crankshaft pilot. Do not use screwdrivers or prybars to remove the flywheel or damage to the flywheel or engine may occur.

Remove the flywheel.
^ Install 2 of the removed flywheel bolts in the 2 holes shown on the flywheel flange.
^ Tighten the 2 bolts evenly to push the flywheel off the crankshaft pilot.





4. Remove the engine/transmission spacer plate.





5. Mount the engine on a suitable work stand.





6. Disconnect the coolant hose from the thermostat housing.





7. Remove the coolant tube bracket nut.





8. Disconnect the 2 coolant vent hoses from the intake manifold.





9. Disconnect the 2 upper radiator hoses from the intake manifold.





10. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





11. Remove the 2 nuts and the thermostat housing assembly.





12. Disconnect the coolant hose from the charge air cooler (CAC).





13. Loosen the 4 coolant pump pulley bolts.





14. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





15. Remove the bolt, supercharger (SC) drive belt tensioner and the SC drive belt.





16. Remove the power steering tube bracket nut.





17. Remove the power steering tube bracket bolt.





18. Remove the 2 power steering reservoir bracket bolts.





19. Remove the 3 bolts and the power steering pump and reservoir assembly.





20. Disconnect the generator electrical connector.





21. Detach the 2 wiring harness pin-type retainers from the generator.





22. Remove the stud bolt, 2 bolts and the alternator.





23. Remove the bolt and the accessory drive belt tensioner.





24. Remove the stud bolt and the accessory drive belt idler pulley (smooth).





25. Remove the bolt and the accessory drive belt idler pulley (grooved).





26. Remove the 4 bolts and the coolant pump pulley.





27. Remove the 3 bolts and the 3 SC drive belt idler pulleys.





28. Disconnect the 2 EGR tube fittings.
^ Remove the EGR tube.





29. Disconnect and remove the crankcase ventilation tube.





30. Disconnect the throttle position (TP) sensor electrical connector.





31. Disconnect the throttle body (TB) control electrical connector.





32. Remove the 4 bolts and the TB and spacer assembly.
^ Discard the gasket.





33. Disconnect the cylinder head temperature (CHT) sensor electrical connector.