Part 3
Cylinder Head
Removal (Steps 67-97)
67. Remove the bolt and the CMP sensor.
68. Remove the 4 bolts and the coolant pump.
69. Using the special tool, remove the crankshaft pulley bolt and the washer.
^ Discard the bolt.
70. Using the special tool, remove the crankshaft pulley.
71. Using the special tools, remove the crankshaft front seal.
72. Remove the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.
73. Remove the 16 bolts and the engine front cover.
^ Remove and discard the engine front cover gaskets.
^ 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. Use a plastic scraping tool to remove all traces of old sealant.
Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the mating surfaces.
74. CAUTION: Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
NOTE: RH shown, LH similar.
Remove the 8 spark plugs.
75. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
Using the special tool, compress the valve spring and remove the roller follower.
76. Repeat the previous step to remove all the roller followers. Inspect roller followers.
77. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
Remove the hydraulic lash adjusters.
^ Inspect the hydraulic lash adjusters.
78. Remove the crankshaft sensor ring.
79. Remove the 2 bolts and the RH primary timing chain tensioner.
80. Remove the RH primary timing chain tensioner arm.
81. Remove the RH primary timing chain.
82. Remove the 2 bolts and the RH primary timing chain guide.
83. Remove the 2 bolts and the LH primary timing chain tensioner.
84. Remove the LH primary timing chain tensioner arm.
85. Remove the LH primary timing chain.
86. Remove the 2 bolts and the LH primary timing chain guide.
87. Remove the crankshaft sprocket.
LH cylinder head
88. Remove 8 nuts and the LH exhaust manifold.
^ Discard the nuts and gaskets.
89. Clean and inspect the LH exhaust manifold.
90. Remove and discard the 8 LH exhaust manifold studs.
RH cylinder head
91. Remove 8 nuts and the RH exhaust manifold.
^ Discard the nuts and gaskets.
92. Clean and inspect the RH exhaust manifold.
93. Remove and discard the 8 RH exhaust manifold studs.
94. Remove the 3 coolant tube assembly bolts.
Both cylinder heads
95. 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 must be installed. They are a tighten-to-yield design 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.
NOTE: LH shown, RH similar.
Remove the 10 bolts and the cylinder head.
^ Discard the bolts.
^ Remove and discard the cylinder head gaskets.
96. 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.
NOTE: 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 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.
97. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat within 0.010 mm (0.0004 in) from end to end.
NOTE: LH shown, RH similar.
Support the cylinder heads 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).
