Cylinder Head Removal

Cylinder Head Assembly:

Cylinder Head Assembly Legend:

Remove or Disconnect

1. Negative (-) battery cable.
2. Drain engine coolant.
- Raise and suitably support vehicle.
3. Six bolts and right-side engine splash shield from vehicle.
- Lower vehicle.

Accelerator Cable & Throttle Cable:

- Loosen lock nut and adjusting nut and remove accelerator cable from bracket and throttle body (TB).
- Loosen lock nut and adjusting nut and remove throttle cable from bracket and TB (automatic transaxle equipped vehicles).
4. Vacuum hose from the evaporative emissions (EVAP) canister.
5. Intake air temperature (IAT) sensor electrical connector from the air cleaner cap.
- Loosen air cleaner (ACL) hose clamp bolt.
6. Four clips and ACL cover.
7. Generator.
8. Distributor.
9. Front exhaust pipe.
A. Oxygen sensor (O2S).
B. Sub-oxygen sensor (SUB-O2S) (California specification vehicles).
C. Two bolts and front exhaust pipe from mounting bracket.
D. Two nuts, front exhaust pipe and gasket from exhaust manifold (from warm up three way catalytic converter [WU TWC] on California specification vehicles).
E. Two nuts, front exhaust pipe and gasket from muffler pipe.
10. Exhaust manifold.

Upper Heat Insulator:

A. Five bolts and upper heat insulator.

Exhaust Manifold Braces:

B. Three bolts and exhaust manifold brace (two bolts on California specification vehicles).

Exhaust Manifold:

C. Five nuts and exhaust manifold from vehicle.
11. Upper radiator hose from engine coolant outlet housing.
12. Two bolts and engine coolant outlet housing from vehicle.

Thermostat Housing W/Attached Components:

13. Thermostat housing.
A. Engine coolant temperature (ECT) sending unit electrical connector.
B. ECT sensor electrical connector.
C. Idle air control (IAC) valve electrical connector.
D. Lower radiator hose from the thermostat housing.
E. Engine coolant control valve inlet and outlet hoses from thermostat housing.
F. EVAP thermal vacuum valve (TVV) vacuum hoses from thermostat housing.
G. Two engine coolant bypass hoses from thermostat housing.
H. One bolt, two nuts and thermostat housing from vehicle.
14. One nut and left-side engine hanger from engine.
15. Ground strap electrical connector.
16. Manifold absolute pressure (MAP) sensor electrical connector.
17. A/C triple pressure switch electrical connector (if equipped).
18. Engine wire harness from right-side fender.
19. The following hoses from the intake chamber:
- Vacuum sensor hose from fuel filter.
- Brake booster vacuum hose.
- Air conditioning (A/C) vacuum hoses from A/C solenoid vacuum (A/C SV) valve (if equipped).
- Air hose from air pipe.
20. A/C SV valve electrical connector.
21. Exhaust gas recirculation solenoid vacuum (EGR SV) valve (California specification vehicles).
A. EGR SV valve and EGR temperature sensor electrical connectors.
B. Vacuum hose from EGR SV valve.
C. One bolt and EGR SV valve from vehicle.
22. Engine wire clamp.
23. Three bolts and intake manifold brace.
24. Fuel return hose from pressure regulator.

Air Pipe:

25. One bolt, one nut and air pipe from intake manifold.

EGR Valve & Vacuum Modulator:

26. Two bolts, two nuts and EGR valve and two gaskets from vehicle, disconnecting vacuum hoses (California specification vehicles).
27. Vacuum hoses, slide vacuum modulator from bracket and remove modulator from vehicle (California specification vehicles).
28. TB from intake manifold.
A. Two bolts and accelerator bracket.
B. Throttle position (TP) sensor electrical connector.

Throttle Body (TB):

C. Two bolts, two nuts and TB with gasket.
29. Fuel inlet hose clamp bolt.
30. One bolt and intake chamber brace and gasket.
31. Two hose clamps and two positive crankcase ventilation (PCV) hoses from cylinder head cover.
32. Intake chamber cover.
A. Vacuum hose from pressure regulator.

Intake Chamber Cover:

B. Three bolts, two nuts and intake chamber cover with gasket.
33. Fuel rail with injectors.

Fuel Inlet Pipe:

A. Union bolt, two gaskets and fuel inlet pipe from fuel rail.
B. Injector electrical connectors.

NOTICE: Be careful not to drop the injectors when removing fuel rail. Damage to the injectors could result.

Fuel Rail:

C. Two bolts and fuel rail with injectors attached.
D. Injectors from fuel rail.
E. O-ring and grommet from injectors.
F. Four insulators and two spacers from cylinder head.
34. Engine wire harness.
A. A/C compressor electrical connector (if equipped).
B. Oil pressure switch electrical connector.

Engine Wiring Harness Cover:

C. Two bolts and engine wire cover from engine.
D. Fan thermostat switch.
E. Knock sensor (KS) electrical connector.
F. One bolt and engine wire ground strap.
G. Three nuts and engine wire harness retainer.
35. Seven bolts, ground strap, two nuts and intake manifold with gasket.
36. Engine mount from vehicle.
A. Unclip cruise control actuator cover and remove from vehicle (if equipped).
B. Three bolts and set cruise control actuator aside (if equipped).
C. Three bolts and cruise control actuator bracket from vehicle (if equipped).
D. Support engine using a floor jack.
E. Two nuts from engine mount studs.

A/C Pipe Bracket Removal:

F. One bolt, one screw and two-piece A/C pipe bracket from engine mount (if equipped, illustration).

Engine Mount:

G. One bolt, one nut and engine mount reinforcement bracket from vehicle (if equipped, illustration).
H. One bolt and rubber insulator from engine mount.
I. Four bolts and engine mount from vehicle.

Important
- It may be necessary to lower engine to gain clearance for engine mount removal. Be careful not to bend A/C pipe (if equipped) too much or a leak may develop in the A/C system.

37. Timing belt.
38. One bolt and front engine hanger from engine.
39. Three bolts and generator mounting bracket from vehicle.
40. Oil level indicator from guide tube.
41. One bolt and guide tube from vehicle.
- Loosen hose clamp on engine coolant inlet pipe.

Engine Coolant Inlet Pipe:

42. Two nuts and engine coolant inlet pipe from vehicle.
43. Intake and exhaust camshafts.

NOTICE: Cylinder head warping or cracking could result from incorrect bolt removal.

Cylinder Head Bolt Removal Sequence:

44. Cylinder head bolts in sequence shown in the illustration.
45. Cylinder head from dowels on cylinder block and place on wooden blocks on workbench.

NOTICE: When prying cylinder head front block, take care not to damage mating surfaces with pry bar.

Prying Cylinder Head Loose From Block:

- If head is difficult to lift off, gently pry with a bar between the cylinder head and cylinder block projection.