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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1290 (Engine Mechanical - 1.8L (LV6)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
    CAUTION: Refer to BATTERY DISCONNECT CAUTION .
  2. Disconnect the negative battery cable.
  3. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  4. Drain the engine oil.
  5. Remove the serpentine drive belt. Refer to DRIVE BELT REPLACEMENT  .
    Fig 1: Removing Serpentine Drive Belt
    G01546779Courtesy of GENERAL MOTORS CORP.
  6. Remove the generator. Refer to GENERATOR .
  7. Remove the accelerator cable from the throttle body (1).
    Fig 2: Removing Accelerator Cable From Throttle Body
    G01546780Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the intake air temperature (IAT) sensor.
  9. Remove the air cleaner hose and cap assembly (1).

    Disconnect the throttle position (TP) sensor connector.

  10. Disconnect the idle air control (IAC) Valve connector.
  11. Disconnect the manifold absolute pressure (MAP) sensor connector.
  12. Remove the two coolant bypass hose clamps from the throttle body.
  13. Remove the coolant bypass hoses.
    Fig 3: Removing Coolant Bypass Hoses
    G01546781Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the four fuel injector connectors (1).
    Fig 4: Disconnecting Four Fuel Injector Connectors
    G01546782Courtesy of GENERAL MOTORS CORP.
  15. Remove the radiator inlet hose. Refer to RADIATOR HOSE REPLACEMENT - INLET in Engine Cooling.
  16. Remove the following items from the intake manifold:
    • The 2 bolts (3, 4)
    • The fuel injector harness
  17. Position the fuel injector harness above the intake manifold.
  18. Remove the intake manifold support bracket bolts and bracket.
  19. Disconnect all of the necessary vacuum hoses.
  20. Remove the fuel injector harness brackets.
  21. Disconnect the oxygen sensor connector.
  22. Remove the oxygen sensor nuts.
  23. Remove the following components:
    • The oxygen sensor
    • The oxygen sensor gasket
  24. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  25. Remove the following items from the exhaust pipe at the manifold.
    • The two bolts (1, 2)
    • The springs
  26. Remove the exhaust pipe to manifold seal.
    Fig 5: Removing Exhaust Pipe To Manifold Seal
    G01546783Courtesy of GENERAL MOTORS CORP.
  27. On AWD, remove the 1 bolt (1) from the exhaust manifold to the support bracket.
    Fig 6: Removing Bolt From Exhaust Manifold To Support Bracket
    G01546784Courtesy of GENERAL MOTORS CORP.
  28. On 2WD, remove the exhaust manifold support bracket bolt.
    Fig 7: Identifying Exhaust Manifold Support Bracket Bolts
    G01546785Courtesy of GENERAL MOTORS CORP.
  29. On all vehicles, lower the vehicle.
  30. Install the J 28467-A  . Refer to ENGINE SUPPORT FIXTURE  .
  31. Remove the right side engine mount. Refer to ENGINE MOUNT REPLACEMENT  .
  32. Disconnect the two ignition coil connectors.
  33. Disconnect the fuel line at the fuel rail.
  34. Remove the injector fuel rail hold down clamp.
  35. Remove the ignition coils (1, 2, 3, 4).
    Fig 8: Removing Ignition Coils
    G01546786Courtesy of GENERAL MOTORS CORP.
  36. Remove the following items from the cylinder head:
    • The 3 bolts
    • The fuel rail
    • The 2 ground wire bolts
    • The ground wires
  37. Position the injector harness aside.
  38. Remove the heater hose at the cylinder head.
  39. Remove the following items from the cylinder head:
    • The one bolt
    • The water bypass pipe
  40. Remove the following items:
    • The 1 bolt
    • The camshaft sensor
  41. Remove the engine coolant temperature sensor.
  42. Remove the following items from the cylinder head cover:
    • The two PCV hoses
    • The PCV valve
  43. Remove the cylinder head cover from the cylinder head. Refer to CYLINDER HEAD COVER REPLACEMENT   .
  44. Set the number 1 piston to top dead center.
  45. Align the camshaft timing sprockets.
  46. Disconnect the power steering oil pressure switch connector.
  47. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  48. Remove the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - RIGHT in Body Front End.
  49. Remove the left side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - LEFT in Body Front End.
  50. Remove the two power steering pump through bolts and nuts (1).
    Fig 9: Removing Power Steering Pump
    G01546787Courtesy of GENERAL MOTORS CORP.
  51. Remove the power steering pump.
  52. Position the power steering pump aside.
  53. Remove the crankshaft pulley. Refer to CRANKSHAFT PULLEY REPLACEMENT  .
  54. Remove the following items:
    • The crankshaft position sensor bolt (5)
    • The crankshaft position sensor
      • Fig 10: Removing Crankshaft Position Sensor
      G01546788Courtesy of GENERAL MOTORS CORP.
  55. Lower the vehicle.
  56. Remove the drive belt tensioner nut.
  57. Remove the following items:
    • The drive belt tensioner bolt
    • The drive belt tensioner
  58. Remove the following items:
    • The 3 right side engine mounting bracket bolts
    • The engine mounting bracket
  59. Remove the timing chain tensioner bolts (1, 2).
  60. Remove the timing chain tensioner.
    Fig 11: Removing Timing Chain Tensioner
    G01546789Courtesy of GENERAL MOTORS CORP.
  61. Remove the timing chain cover bolts and nuts (1-15).
    Fig 12: Removing Timing Chain Cover
    G01546790Courtesy of GENERAL MOTORS CORP.
  62. Remove the timing chain cover.
  63. Remove the crank sensor reluctor.
  64. Remove the following items:
    • The timing chain slipper bolt
    • The slipper
  65. Remove the following items:
    • The crankshaft sprocket
    • The timing chain
      Fig 13: Removing Crankshaft Sprocket And Timing Chain
      G01546791Courtesy of GENERAL MOTORS CORP.
  66. Remove the camshaft sprocket bolts.
  67. Remove the camshaft sprockets.
    Fig 14: Removing Camshaft Sprockets
    G01546792Courtesy of GENERAL MOTORS CORP.
  68. Remove the following items in sequence:
    • The camshaft bearing cap bolts
    • The camshaft bearing caps
      • Fig 15: Identifying Camshaft Bearing Cap Bolts Removal Sequence
      G01546793Courtesy of GENERAL MOTORS CORP.
  69. Remove the camshafts.
  70. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location.

    Important:  Use a wooden block in order to protect the oil pan when lifting the engine.

  71. Use a floor jack in order to raise the engine.
  72. Reposition the holding fixture.
  73. Remove the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT  .
  74. Remove the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT (AWD) or EXHAUST MANIFOLD REPLACEMENT (2WD) in Engine Exhaust.
  75. Remove the following items in sequence:
    • The cylinder head bolts
    • The cylinder head washers
      Fig 16: Identifying Cylinder Head Bolts Removal Sequence
      G01546794Courtesy of GENERAL MOTORS CORP.
  76. Remove the cylinder head.
    Fig 17: Removing Cylinder Head
    G01546795Courtesy of GENERAL MOTORS CORP.
  77. Remove the cylinder head gasket (1).
    Fig 18: Removing Cylinder Head Gasket
    G01546796Courtesy of GENERAL MOTORS CORP.
  78. Clean the cylinder block mating surfaces.
    Fig 19: Cleaning Cylinder Block Mating Surfaces
    G01546797Courtesy of GENERAL MOTORS CORP.
  79. Clean the cylinder head mating surface.
  80. Clean the timing chain cover mating surface.
    Fig 20: Cleaning Cylinder Head Mating Surface
    G01546798Courtesy of GENERAL MOTORS CORP.
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