Cylinder Head

Special Tool(s)

	3 Jaw Puller 303-D121 or equivalent
	Compressor, Valve Spring 303-452 (T93P-6565-AR)
	Remover, Oil Seal 303-409 (T92C-6700-CH)
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent

NOTICE: 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. For additional information, refer to Engine in this section.

2. Remove the 8 flywheel bolts.

3. NOTICE: 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. If equipped, disconnect the coolant hose from the oil cooler.

7. If equipped, disconnect the coolant hose from the thermostat housing.

8. If equipped, remove the coolant tube bracket nut and the coolant tube.

9. Remove the engine vent hose from the intake manifold.

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

11. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.

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

13. Disconnect the coolant hose from the Charge Air Cooler (CAC).

14. Remove the 3 bolts and the alternator.

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

16. Remove the 3 bolts and the accessory drive belt idler pulley.

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

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

19. Using the Strap Wrench, remove the 4 bolts and the coolant pump pulley.

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

21. Disconnect the 2 EGR tube fittings.
    • Remove the EGR tube.

22. Disconnect and remove the crankcase ventilation tube.

23. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.

24. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.

25. Remove the 4 bolts and the Throttle Body (TB) and spacer assembly.
    • Discard the gasket.

26. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.

27. Detach the 2 wiring harness pin-type retainers (1 shown) from the coolant tube assembly bracket.

28. Disconnect the bubbler hose from the SC .

29. Remove the 2 bolts and the wiring harness retaining bracket.

30. Detach the 2 wiring harness pin-type retainers.

31. Disconnect the PCV valve electrical connector.

32. Disconnect the 4 RH fuel injector electrical connectors.

33. Disconnect the fuel rail pressure and temperature sensor electrical connector.

34. Remove the nut and position aside the RH radio interference capacitor.

35. Disconnect the EGR valve electrical connector.

36. Detach the 2 wiring harness retainers from the RH coil-on-plug cover stud bolts.

37. Detach the wiring harness retainers from the RH valve cover stud bolts.

38. Remove the nut and the A/C tube support bracket.

39. Remove the 2 stud bolts and the RH coil-on-plug cover.

40. Disconnect the 4 RH coil-on-plug electrical connectors.
    • Remove the 4 RH coil-on-plugs.

41. Disconnect the Camshaft Position (CMP) sensor electrical connector.

42. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.

43. Disconnect the 4 LH fuel injector electrical connectors.

44. Remove the nut and position aside the LH radio interference capacitor.

45. Detach the wiring harness retainers from the LH valve cover stud bolts.

46. Remove the 2 bolts and the LH coil-on-plug cover.

47. Disconnect the 4 LH coil-on-plug electrical connectors.
    • Remove the 4 LH coil-on-plugs.

48. Remove the wiring harness assembly from the engine.

49. Disconnect the intake manifold-to-coolant tube assembly hose.

50. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Remove the 14 bolts and the intake manifold assembly.
    • Remove and discard the 2 intake manifold gaskets.

51. Remove the 3 coolant tube assembly bolts.

52. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

    NOTE: Oil cooler shown, oil cooler thermostat similar.

    Remove the 6 bolts and the oil cooler.
    • Discard the oil cooler and the gaskets.

53. Remove the 8 bolts and the oil filter adapter.
    • Remove and discard the oil filter adapter gasket.

54. Remove the oil level indicator, the bolt and the oil level indicator tube.
    • Remove and discard the oil level indicator tube O-ring seal.

55. NOTE: The RH engine support insulator bracket must be removed to access the RH block drain plug.

    If equipped with a cylinder block drain, remove the stud bolt, 3 bolts and the RH engine support insulator bracket.

56. NOTE: LH shown, RH similar.

    If equipped, remove the LH and RH block drain plugs.

57. NOTICE: 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.

    Remove the bolts, stud bolts and RH valve cover.
    • Remove and discard the gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.

58. NOTICE: 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.

    Remove the bolts, stud bolts and LH valve cover.
    • Remove and discard the gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.

59. Remove the bolt and the Crankshaft Position (CKP) sensor.

60. Remove the bolt and the CMP sensor.

61. Remove the 4 bolts and the coolant pump.

62. Using the Strap Wrench, remove the crankshaft pulley bolt and the washer.
    • Discard the bolt.

63. Using the 3 Jaw Puller, remove the crankshaft pulley.

64. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

65. Remove the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.

66. Remove the 16 bolts and the engine front cover.
    • Remove and discard the engine front cover gaskets.

    • NOTICE: 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.

67. NOTICE: 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.

68. NOTICE: 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 Valve Spring Compressor, compress the valve spring and remove the roller follower.

69. Repeat the previous step to remove all the roller followers. Inspect roller followers. Refer to Section 303-00 .

70. NOTICE: 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. Refer to Section 303-00 .

71. Remove the crankshaft sensor ring.

72. Remove the crankshaft washer.

73. Remove the 2 bolts and the RH primary timing chain tensioner.

74. Remove the RH primary timing chain tensioner arm.

75. Remove the RH primary timing chain.

76. Remove the 2 bolts and the RH primary timing chain guide.

77. Remove the 2 bolts and the LH primary timing chain tensioner.

78. Remove the LH primary timing chain tensioner arm.

79. Remove the LH primary timing chain.

80. Remove the 2 bolts and the LH primary timing chain guide.

81. Remove the crankshaft sprocket.

LH cylinder head

82. Disconnect the 2 LH Heated Oxygen Sensor (HO2S) wire retainers.

83. Remove 8 nuts and the LH exhaust manifold.
    • Discard the nuts and gaskets.

84. Clean and inspect the LH exhaust manifold. Refer to Section 303-00 .

85. Remove and discard the 8 LH exhaust manifold studs.

RH cylinder head

86. Remove 8 nuts and the RH exhaust manifold.
    • Discard the nuts and gaskets.

87. Clean and inspect the RH exhaust manifold. Refer to Section 303-00 .

88. Remove and discard the 8 RH exhaust manifold studs.

89. Remove the 3 coolant tube assembly bolts.

Both cylinder heads

90. NOTICE: 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.

    NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

    NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

    NOTICE: 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.

    NOTICE: 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.

91. NOTICE: 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.

92. NOTE: LH shown, RH similar.

    Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. Refer to Section 303-00 .