Cylinder Head: Removal

WARNING: This page is about a different variant/trim than selected.

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
Remove the cowl panel grille. Refer to: Cowl Panel Grille .
NOTE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press straight upward on the underside of the cover at the attachment points may result in damage to the cover or engine components.
1. Place your hand under the engine appearance cover at each grommet location and push straight up to release each grommet from the studs.
2. After all of the grommets have been released from the studs, remove the appearance cover from the engine.
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Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Remove the battery tray. Refer to: Battery Tray .
Drain the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
Remove the following items:
1. Remove the intake manifold. Refer to: Intake Manifold .
2. NOTE: Make sure the brake vacuum pump adapter is removed from the intake camshaft before installing the special tool 303- 1565 (Camshaft Alignment Tool) or damage may occur due to incorrect valve timing.
  
  Remove the camshafts. Refer to: Camshafts .
Remove and discard the turbocharger nuts.

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Remove and discard the upper cylinder head studs.

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- Detach and disconnect the fuel rail electrical connector.
- Detach the wiring harness retainers.
- Remove the fuel rail insulator shield.
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Disconnect the fuel injector and the FRP sensor electrical connectors.

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Remove the bolt and ground wire.

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Disconnect the CHT sensor wiring harness electrical connector.

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Remove the bolts and position the water outlet aside.

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NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

Remove the valve tappets.

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- Remove the cylinder head bolts.
- Discard the bolts.
Fig 1: Cylinder Head Bolts Loosening Sequence
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NOTE: When removing or installing the cylinder head, use care to prevent excessive movement of the turbocharger. Excessive movement may cause damage to the turbocharger oil return tube resulting in an engine oil leak.
1. Lift the cylinder head to clear the locating dowels in the cylinder block.
2. Slide the cylinder head and studs out of the turbocharger and remove.
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Remove and discard the lower cylinder head studs and turbocharger gasket.

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Remove and discard the cylinder head gasket.

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NOTE: 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: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

Clean the cylinder head sealing surfaces.

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Inspect the cylinder head sealing surfaces.

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- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
NOTE: Replace gasket if damaged.

Inspect the coolant outlet gasket and replace as necessary.

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