Removal Procedure

Special Tools

• EN 38188  Cylinder Head Broken Bolt Extractor Kit or equivalent aftermarket tool
• EN 45059  Angle Meter

Equivalent regional tools: Special Tools

1. Fuel Pump - Remove - Fuel Pump Replacement
2. Drain the cooling system. Cooling System Draining and Filling (GE 47716) , or Cooling System Draining and Filling (Static Fill)
3. Drain the engine oil. Engine Oil and Oil Filter Replacement 

4. Courtesy of GENERAL MOTORS COMPANY

   Camshaft Cover (3) - Remove - Camshaft Cover Replacement 

5. Intake Manifold - Remove - Intake Manifold Replacement 
6. Exhaust Manifold - Remove - Exhaust Manifold Replacement (LTG)
7. Fig 1: Exploded View Of Engine Front Cover, Bolts And Seal

   Courtesy of GENERAL MOTORS COMPANY

   Engine Front Cover (1) - Remove - Engine Front Cover Replacement 

8. Remove the camshaft timing chain and tensioner. Camshaft Timing Chain and Tensioner Removal 
9. Remove the intake and exhaust camshafts, bearing cap, and lash adjusters. Intake and Exhaust Camshaft, Bearing Cap, and Lash Adjuster Removal 

10. Courtesy of GENERAL MOTORS COMPANY

    Ground Cable Bolt (1) - Remove

11. Wiring Harness Retainer (2) - Remove
12. Ground Cable (3) - Remove [2x]
13. Remove the ground wire bolt and wire at the left front of the cylinder head and reposition the harness retainer
14. Exhaust Camshaft Position Sensor Electrical Connector (2) - Disconnect
15. Intake Camshaft Position Sensor Electrical Connector (3) - Disconnect

16. Courtesy of GENERAL MOTORS COMPANY

    NOTE:

    Remove ONLY the water outlet bolts (2) and seal (3), the hoses will remain attached to the water outlet.

    Water Outlet Bolt (2) - Remove [2x] - Water Outlet Replacement (LTG)

17. Separate the water outlet (4) from the cylinder head.
18. Water Outlet Seal (3) - Remove and DISCARD
19. Fuel Injection Fuel Rail Assembly - Remove - Fuel Injection Fuel Rail Assembly Replacement
20. Fig 2: Identifying Cylinder Head Bolts in Sequence

    Courtesy of GENERAL MOTORS COMPANY

    Loosen the cylinder head to the block bolts in sequence.

21. Courtesy of GENERAL MOTORS COMPANY

    Cylinder Head Bolt (1) - Remove and DISCARD [10x]

CAUTION:

In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks.

22. Cylinder Head (2) - Remove
23. Cylinder Head Gasket (3) - Remove and DISCARD
NOTE:

There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket.

24. Clean cylinder head and block sealing surfaces using the following guidelines.
    • Use a gasket scraper to clean the cylinder head and cylinder block gasket surfaces.
    • Do not scratch or gouge any surface.
    • The feel of the gasket surface is important, not the appearance.
    • Do not gouge or scrape the combustion chamber surfaces.
    • Do not use any other method or technique to clean these gasket surfaces.
WARNING:

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

25. Clean the old sealer/lube and dirt from the bolt holes using the following guidelines.
    • When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
    • Do not use a tap to clean the cylinder head bolt holes.
    • Clean the bolt holes with a nylon bristle brush.
26. Remove any broken long cylinder head bolts using the EN 38188  kit.
27. For cylinder head disassembly refer to Cylinder Head Disassemble .
28. For cylinder head cleaning and inspection refer to Cylinder Head Cleaning and Inspection .