Removal - Cylinder Head

Fig 1: Air Inlet System - 2.4L Turbo

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1 - CLEAN AIR HOSE

2 - AIR CLEANER HOUSING

3 - FRESH AIR INLET DUCT

4 - PDC MOUNTING BRACKET

Perform fuel system pressure release procedure before attempting any repairs , (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) .
Remove clean air hose (1) and air cleaner housing (2) (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .

Disconnect negative cable from battery.

Fig 2: FAN - RADIATOR MOUNTING

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1 - MOUNTING FASTENERS

2 - COOLING FAN ASSEMBLY

3 - COOLING FAN MOTOR

4 - DRAIN COCK

Open drain cock (4) to drain cooling system into a clean container.

Remove upper intake manifold, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) .

Fig 3: Dipstick Tube

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1 - DIPSTICK TUBE

2 - COOLANT TEMPERATURE SENSOR

3 - SCREW

Remove fastener (3) attaching dipstick tube (1) to lower intake manifold. See Fig 3.

Fig 4: Lower Intake Manifold Support Bracket - 2.4L Turbo

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1 - UPPER INTAKE MANIFOLD

2 - LOWER INTAKE MANIFOLD

3 - SUPPORT BRACKET

4 - DIPSTICK TUBE SCREW

Turbocharger equipped vehicles: Remove lower intake manifold support bracket (3). See Fig 4.
Disconnect the fuel supply line quick-connect at the fuel rail assembly (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
Remove heater tube support bracket from cylinder head.
Remove upper radiator hose. Disconnect heater hoses from thermostat housing.
Disconnect engine coolant temperature sensor connector.

Remove accessory drive belts (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .

Fig 5: Turbocharger Brackets And Heat Shields

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1 - UPPER/LOWER HEAT SHIELDS

2 - TURBOCHARGER SUPPORT BRACKET

3 - ELBOW

4 - ELBOW SUPPORT BRACKET

Raise vehicle on a suitable hoist.
Disconnect exhaust pipe from manifold.

Turbocharger equipped vehicles: . See Fig 5

Remove turbocharger heat shields (1)
Remove elbow support bracket (4)
Remove turbocharger support bracket (2)
Remove elbow (3)

Fig 6: Turbocharger Lines and Hoses

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1 - OIL SUPPLY LINE

2 - COOLANT RETURN LINE

3 - COOLANT SUPPLY LINE

4 - OIL RETURN TUBE

Turbocharger equipped vehicles: (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - REMOVAL) . See Fig 6.
1. Remove oil return tube (4)
2. Remove oil supply line (1)
3. Remove coolant supply line (3)
4. Remove coolant return line (2)
Disconnect ignition coil wiring connector. Remove ignition coil and plug wires from engine.
Disconnect camshaft position sensor wiring connector.
Remove timing belt and camshaft sprockets (Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL) .

Remove timing belt idler pulley and rear timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL) .

Fig 7: Power Steering Fluid Reservoir and Bracket

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1 - POWER STEERING RESERVOIR

2 - BOLT

3 - BRACKET

Non-Turbo equipped vehicles: Remove fasteners (2) securing power steering pump fluid reservoir (1) and bracket (3) to cylinder head.
Remove cylinder head cover (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL) .
Remove camshafts (Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL) .
NOTE: Identify rocker arm location for reassembly prior to removal.
Remove rocker arms.

Fig 8: Cylinder Head Bolt Removal
Courtesy of DAIMLERCHRYSLER CORP.
Remove cylinder head bolts in the reverse sequence of tightening. See Fig 8.
Remove cylinder head from engine block.
Inspect and clean cylinder head and block sealing surfaces. Refer to CLEANING and INSPECTION for procedures.

NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.