Cylinder Head: Removal
WARNING: This page is about a different variant/trim than selected.
NOTE:
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTE:
During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan may cause engine failure.
- With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
- Release the fuel system pressure. Refer to: Fuel System Pressure Release .
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- Remove the oil drain bolt and drain the engine oil. Use the General Equipment: Oil Drain Equipment
- Install the oil drain bolt.
Torque:
21 lb.ft (28 Nm)
- Remove and discard the engine oil filter.
- Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
- Disconnect the CMS (catalyst monitor sensor) and HO2S electrical connectors, detach the wire harness retainers.
- Remove the bolts and the exhaust manifold heat shield.
- Remove the retainers and the underbody shield.
- Remove the exhaust manifold bracket bolts.
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NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
Support the exhaust flexible pipe with a support wrap or suitable splint.
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- Remove and discard the nuts.
- Position aside the exhaust system.
- Remove and discard the exhaust system gasket.
- Remove the bolts for the exhaust manifold.
- Remove and discard the nuts. Position back the exhaust manifold.
- Remove and discard the exhaust manifold gasket.
- Remove and discard the exhaust manifold studs.
- Remove the following items:
- Remove the air cleaner. Refer to: Air Cleaner .
- Remove the intake manifold. Refer to: Intake Manifold .
- Remove the fuel injectors. Refer to: Fuel Injectors .
- Remove the camshafts. Refer to: Camshafts .
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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.NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
Remove the valve tappets.
- Inspect and install new parts, as necessary.
- Remove the EGR tube.
- Disconnect the EGR electrical connector.
- Position aside the coolant hose clip.
- Disconnect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the EGR valve coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
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- Remove the bolts and the cylinder head.
- Discard the bolts.
- Remove and discard the cylinder head gasket.