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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1352 (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 2004 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Engine Top Cover, Plastic Retainers And Fasteners
    GM856569Courtesy of GENERAL MOTORS CORP.
  1. Remove the 2 engine cover fasteners.
  2. Remove the 2 engine cover plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure (FWD) or Fuel Pressure Relief Procedure (AWD) in Engine Controls-1.8L (LV6).
    5. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  5. Disconnect the negative battery cable.
  6. Remove the right side engine splash shield. Refer to Splash Shield Replacement - Engine - Right in Body Front End.
  7. Remove the left side engine splash shield. Refer to Splash Shield Replacement - Engine - Left in Body Front End.
  8. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  9. Drain the engine oil.
  10. Lower the vehicle.
    11. Fig 2: Identifying Serpentine Drive Belt Routing
    GM244267Courtesy of GENERAL MOTORS CORP.
  11. Remove the serpentine drive belt. Refer to Drive Belt Replacement .
  12. Remove the generator. Refer to Generator Replacement in Engine Electrical.
    13. Fig 3: Throttle Body And Vacuum Hose Connector
    GM234418Courtesy of GENERAL MOTORS CORP.
  13. Remove the accelerator cable from the throttle body (1).
  14. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
  15. Disconnect the EVAP canister purge valve vacuum hoses.
  16. Disconnect the air cleaner housing vacuum hose.
    17. Fig 4: Air Cleaner Hose And Cap Assembly
    GM847992Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the intake air temperature (IAT) sensor.
  18. Remove the air cleaner hose and cap assembly (1).

    Disconnect the throttle position (TP) sensor connector.

  19. Disconnect the idle air control (IAC) Valve connector.
  20. Disconnect the manifold absolute pressure (MAP) sensor connector.
  21. Remove the two coolant bypass hose clamps from the throttle body.
  22. Remove the coolant bypass hoses.
    23. Fig 5: Fuel Injector Connectors And Harness
    GM856574Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the four fuel injector connectors (1).
  24. Remove the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  25. Remove the following items from the intake manifold:
    • The 2 bolts (3, 4)
    • The fuel injector harness
  26. Position the fuel injector harness above the intake manifold.
  27. Remove the intake manifold support bracket bolts and bracket.
  28. Remove the fuel injector harness brackets.
  29. Disconnect the oxygen sensor connector.
  30. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Position 1 (FWD) or Heated Oxygen Sensor Replacement - Position 1 (AWD) in Engine Controls-1.8L (LV6).
  31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    32. Fig 6: Exhaust Pipe Bolts And Springs
    GM236842Courtesy of GENERAL MOTORS CORP.
  32. Remove the following items from the exhaust pipe at the manifold.
    • The two bolts (1, 2)
    • The springs
  33. Remove the exhaust pipe to manifold seal.
    34. Fig 7: Exhaust Support Bracket Bolt
    GM234425Courtesy of GENERAL MOTORS CORP.
  34. On AWD, remove the 1 bolt (1) from the exhaust manifold to the support bracket.
    35. Fig 8: Exhaust Manifold Support Bracket
    GM824940Courtesy of GENERAL MOTORS CORP.
  35. On 2WD, remove the exhaust manifold support bracket bolt.
  36. On all vehicles, lower the vehicle.
  37. Disconnect the two ignition coil connectors.
  38. Remove the ignition coil harness retaining bolts, then position harness aside.
  39. Disconnect the fuel line at the fuel rail.
  40. Remove the injector fuel rail hold down clamp.
    41. Fig 9: Identifying Ignition Coils
    GM621682Courtesy of GENERAL MOTORS CORP.
  41. Remove the ignition coils (1, 2, 3, 4).
  42. Remove the following items from the cylinder head:
    • The 3 bolts
    • The fuel rail
    • The 2 ground wire bolts
    • The ground wires
  43. Remove the heater hose at the cylinder head.
  44. Remove the following items from the cylinder head:
    • The one bolt
    • The water bypass pipe
  45. Disconnect the cam sensor electrical connector.
  46. Remove the following items:
    • The 1 bolt
    • The camshaft sensor
  47. Disconnect the engine coolant temperature sensor electrical connector.
  48. Disconnect the camshaft position actuator solenoid valve electrical connector.
  49. Remove the bolt and camshaft position actuator solenoid valve and O-ring.
  50. Remove the camshaft position actuator oil filter plug, filter and O-ring.
  51. Remove the two PCV hoses from the cylinder head cover.
  52. Remove the cylinder head cover from the cylinder head. Refer to Cylinder Head Cover Replacement .
  53. Disconnect the power steering oil pressure switch connector.
  54. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    55. Fig 10: Power Steering Pump Nuts And Bolts
    GM236875Courtesy of GENERAL MOTORS CORP.
  55. Remove the two power steering pump through bolts and nuts (1).
  56. Remove the power steering pump.
  57. Position the power steering pump aside.
  58. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
    59. Fig 11: Lower Drive Belt Tensioner Bolt
    GM234378Courtesy of GENERAL MOTORS CORP.
  59. Disconnect the crankshaft sensor electrical connector, then remove the following items:
    • The crankshaft position sensor bolt (5)
    • The crankshaft position sensor
  60. Lower the vehicle.
  61. Set the number 1 piston to top dead center.
  62. Align the camshaft timing sprockets.
  63. Support the engine with a floor jack. Be sure to place a block of wood between the floor jack and the engine.
  64. Remove the drive belt tensioner nut.
  65. Raise the engine, then remove the following items:
    • The drive belt tensioner bolt
    • The drive belt tensioner
  66. Remove the following items:
    • The 6 right side engine mount bolts
    • The engine mount
    67. Fig 12: Timing Chain Tensioner Bolts
    GM234178Courtesy of GENERAL MOTORS CORP.
  67. Remove the timing chain tensioner bolts (1, 2).
  68. Remove the timing chain tensioner.
  69. Remove the engine mount bracket as follows:
    • Remove the 3 bolts
    • Remove the bracket
    70. Fig 13: Timing Chain Cover Bolts And Nuts
    GM234182Courtesy of GENERAL MOTORS CORP.
  70. Remove the timing chain cover bolts and nuts (1-15).
  71. Remove the timing chain cover.
  72. Remove the crank sensor reluctor.
  73. Remove the following items:
    • The timing chain slipper bolt
    • The slipper
    74. Fig 14: Removing Timing Chain And Crankshaft Sprocket
    GM234188Courtesy of GENERAL MOTORS CORP.
  74. Remove the following items:
    • The crankshaft sprocket
    • The timing chain
    75. Fig 15: View Of Sprocket Locating Pins
    GM625493Courtesy of GENERAL MOTORS CORP.
  75. Remove the camshaft sprocket bolts.
  76. Remove the camshaft sprockets.
    77. Fig 16: Camshaft Bearing Cap Bolts And Bearing Caps
    GM234080Courtesy of GENERAL MOTORS CORP.
  77. Remove the following items in sequence:
    • The camshaft bearing cap bolts
    • The camshaft bearing caps
  78. Remove the camshafts.
  79. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location.
    80. IMPORTANT: Use a wooden block in order to protect the oil pan when lifting the engine.
  80. Use a floor jack in order to raise the engine.
  81. Remove the intake manifold. Refer to Intake Manifold Replacement .
  82. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (2WD) or Exhaust Manifold Replacement (AWD) in Engine Exhaust.
    83. Fig 17: Cylinder Head Washers And Bolts
    GM234516Courtesy of GENERAL MOTORS CORP.
  83. Remove the following items in sequence:
    • The cylinder head bolts
    • The cylinder head washers
    84. Fig 18: Removing Cylinder Head
    GM234526Courtesy of GENERAL MOTORS CORP.
  84. Remove the cylinder head.
    85. Fig 19: Cylinder Head Gasket
    GM235541Courtesy of GENERAL MOTORS CORP.
  85. Remove the cylinder head gasket (1).
    86. Fig 20: Cleaning Cylinder Block Mating Surfaces
    GM234571Courtesy of GENERAL MOTORS CORP.
  86. Clean the cylinder block mating surfaces.
    87. Fig 21: Cleaning Cylinder Head Mating Surface
    GM234792Courtesy of GENERAL MOTORS CORP.
  87. Clean the cylinder head mating surface.
  88. Clean the timing chain cover mating surface.
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