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Cylinder Head And Gasket Replacement: Removal

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable.
  2. Disconnect intake air temperature (IAT) sensor connector.
  3. Loosen clamp at air cleaner assembly.
  4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
  5. Loosen clamp at throttle body assembly.
  6. Disconnect PVC fresh air vent hose at cam cover.
  7. Remove outlet resonator/duct assembly.
  8. Remove air cleaner assembly hold-down bolt.
  9. Remove air cleaner assembly.
    Fig 1: Removing Outlet Resonator/Duct Assembly
    G01039214Courtesy of GENERAL MOTORS CORP.
  10. Remove ignition module bolts.
  11. Remove ignition module assembly.
    Fig 2: Removing Ignition Module Assembly
    G01039215Courtesy of GENERAL MOTORS CORP.
  12. Disconnect ECM electrical connector and ground at ECM.
  13. Remove oil level indicator bolt to manifold.
  14. Disconnect electrical connector at throttle body.
  15. Disconnect electrical connector at fuel injector harness and attachment at bottom of intake manifold.
  16. Disconnect electrical connector at purge solenoid and MAP sensor.
  17. Disconnect vacuum hose at brake booster.
  18. Disconnect coolant pipe bracket bolts to front of cylinder head.
    Fig 3: Disconnecting ECM Electrical Connector And Ground At ECM
    G01039216Courtesy of GENERAL MOTORS CORP.
  19. Disconnect de-gas hose at clamp at cylinder head and unclip from fuel rail. Position away from cam cover assembly.
  20. Disconnect ground strap at rear of cam cover assembly.
    Fig 4: Disconnecting Ground Strap At Rear Of Cam Cover Assembly
    G01039217Courtesy of GENERAL MOTORS CORP.
  21. Relieve fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  22. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
    Fig 5: Disconnecting Gauge Bar Set
    G01039218Courtesy of GENERAL MOTORS CORP.
  23. Disconnect fuel rail bracket and bolt at rear of cam cover.
    Fig 6: Disconnecting Fuel Rail Bracket
    G01039219Courtesy of GENERAL MOTORS CORP.
    CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.
    NOTE: An open-end wrench must be used to support the fuel line-to-rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
  24. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
    Fig 7: Loosening Transfer Line Fitting At Fuel Rail
    G01039220Courtesy of GENERAL MOTORS CORP.
  25. Position fuel line away from cam cover assembly.
  26. Remove cam cover assembly bolts.
  27. Remove cam cover assembly.
    Fig 8: Removing Cam Cover Assembly
    G01039221Courtesy of GENERAL MOTORS CORP.
    NOTE: To avoid valve to piston contact, No. 1 piston must be positioned at approximately 60° before top dead center (BTDC). Pistons are properly positioned when diamond shaped hole on intake camshaft sprocket is located at 12 o'clock.

    IMPORTANT:  To rotate camshaft(s), use a 24 mm open-end wrench on camshaft flats. Camshaft(s) should be rotated in a clockwise direction only (facing camshaft sprockets from passenger side of vehicle).

  28. Locate the No. 1 piston to approximately 60° before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.
    Fig 9: Rotating Camshafts
    G01039222Courtesy of GENERAL MOTORS CORP.
  29. Remove upper timing chain guide.
    Fig 10: Removing Upper Timing Chain Guide
    G01039223Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The timing chain tensioner must be removed to unload chain tension before timing chain is removed. If it is not removed, the timing chain may bind and be difficult to remove.

  30. Remove timing chain tensioner.
    Fig 11: Removing Timing Chain Tensioner
    G01039224Courtesy of GENERAL MOTORS CORP.
  31. Remove fixed timing chain guide access plug.
  32. Using a magnetic socket, remove upper fixed guide bolt.
    Fig 12: Removing Upper Fixed Guide Bolt
    G01039225Courtesy of GENERAL MOTORS CORP.
  33. Install Engine Three Bar Fixture SA9105E set up for SUV application. (Also, use Engine Support Adapter J45122 with long hooks from Engine Support Fixture Adaptor J43405).
    Fig 13: Installing Engine Three Bar Fixture
    G01039226Courtesy of GENERAL MOTORS CORP.
  34. Remove right-hand engine mount-to-bracket bolts.
  35. Remove right-hand mount assembly nuts.
  36. Remove right-hand engine mount assembly.
    Fig 14: Removing Right-Hand Engine Mount
    G01039227Courtesy of GENERAL MOTORS CORP.
  37. Remove right-hand mount bracket.
  38. Remove right-hand engine mount bracket.
  39. Raise vehicle on hoist.
  40. Remove right wheel and splash shield.

    IMPORTANT:  Do not rest engine assembly on oil pan plug on side of oil pan near crankshaft pulley or an oil leak may result.

  41. Install block of wood (1x2x4) between oil pan and cradle.
  42. Install Accessory Belt Tensioner Unloader J44811 tool.
  43. Remove accessory drive belt.
  44. Remove tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.
    Fig 15: Removing Right-Hand Mount Bracket
    G01039228Courtesy of GENERAL MOTORS CORP.
  45. Remove tensioner assembly.
    Fig 16: Removing Tensioner Assembly
    G01039229Courtesy of GENERAL MOTORS CORP.
  46. Install Crankshaft Pulley Holder J38122A.
    Fig 17: Installing Crankshaft Pulley Holder
    G01039230Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a three-jaw puller.

  47. Remove crankshaft balancer pulley bolt and pulley. Discard pulley bolt.
    Fig 18: Removing Crankshaft Balancer Pulley Bolt And Pulley
    G01039231Courtesy of GENERAL MOTORS CORP.
    NOTE: To avoid damage to the front cover assembly, do not pry against cover.
  48. Remove front cover assembly bolts.
  49. Remove lower water pump assembly bolt.
  50. Remove front cover assembly and gasket.
    Fig 19: Removing Front Cover Assembly And Gasket
    G01039232Courtesy of GENERAL MOTORS CORP.
  51. Remove adjustable guide bolt.
    Fig 20: Removing Adjustable Guide Bolt
    G01039233Courtesy of GENERAL MOTORS CORP.
  52. Remove lower fixed guide bolt.
  53. Remove fixed guide.
    Fig 21: Removing Fixed Guide
    G01039234Courtesy of GENERAL MOTORS CORP.
  54. Drain coolant system.
  55. Remove upper radiator hose from cylinder head.
    Fig 22: Removing Upper Radiator Hose From Cylinder Head
    G01039235Courtesy of GENERAL MOTORS CORP.
  56. Remove exhaust manifold pipe to manifold nuts.
  57. Disconnect electrical connectors at front and rear oxygen sensors.
  58. Remove down pipe to intermediate pipe nuts.
  59. Remove down pipe assembly.
  60. Lower vehicle.
    Fig 23: Removing Down Pipe To Intermediate Pipe Nuts
    G01039236Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
  61. Use a 24 mm wrench to hold camshaft assembly while removing the exhaust sprocket bolt. Discard bolt.
  62. Remove exhaust sprocket.
    Fig 24: Removing Exhaust Sprocket
    G01039237Courtesy of GENERAL MOTORS CORP.
  63. Remove adjustable guide through the top of cylinder head.
    Fig 25: Removing Adjustable Guide
    G01039238Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
  64. Use a 24 mm wrench to hold camshaft assembly while removing intake sprocket bolt. Discard bolt.
  65. Remove intake sprocket.
  66. Remove timing chain assembly through top of cylinder head.
  67. Remove timing chain drive sprocket from crankshaft.
    Fig 26: Removing Intake Sprocket And Timing Chain Drive Sprocket
    G01039239Courtesy of GENERAL MOTORS CORP.
    NOTE: Replace timing chain guides if wear exceeds 1.12 mm (0.045 in.).
  68. Inspect timing chain guide for wear.
  69. Inspect timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on chain.
    Fig 27: Inspecting Timing Chain And Sprockets
    G01039240Courtesy of GENERAL MOTORS CORP.
  70. Install floor jack with block of wood and support engine at center of oil pan.
  71. Remove engine three bar engine support fixture.
    Fig 28: Removing Engine Three Bar Engine Support Fixture
    G01039241Courtesy of GENERAL MOTORS CORP.
  72. Remove cylinder head bolts using loosening sequence.
    Fig 29: Removing Cylinder Head Bolts
    G01039242Courtesy of GENERAL MOTORS CORP.
  73. With assistance, remove cylinder head from block with exhaust and intake manifold attached.
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