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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 681 (Engine Mechanical - 8.1L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement - Right >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: ECT Sensor & Clip At Cylinder Head
    GM742643Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  2. Remove the intake manifold. Refer to Intake Manifold Replacement .
  3. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  4. Remove the engine coolant temperature (ECT) sensor clip from the bracket.
  5. Remove the ECT sensor from the cylinder head.
    6. Fig 2: ECT Sensor Bracket & Bolt
    GM742645Courtesy of GENERAL MOTORS CORP.
  6. Remove the ECT sensor bracket bolt and bracket.
    7. Fig 3: Heater Inlet & Outlet Hose Bracket
    GM750695Courtesy of GENERAL MOTORS CORP.
  7. Remove the heater inlet and outlet hoses from the hose bracket.
  8. Remove the heater hose bracket bolts and bracket from the cylinder head.
  9. Remove the water crossover. Refer to WATER CROSSOVER REPLACEMENT (8.1L ENGINE) in Engine Cooling.
  10. Remove the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (8.1L ENGINE) in Engine Exhaust.
    11. Fig 4: View Of Right Cylinder Head Bolts
    GM470989Courtesy of GENERAL MOTORS CORP.
  11. Remove and discard the cylinder head bolts (1, 2, and 3).
    12. Fig 5: View Of Right Cylinder Head And Alignment Pin
    GM470991Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Place the cylinder head on two wood block to prevent damage to the sealing surface.
  12. Remove the cylinder head.
    13. Fig 6: View Of Right Cylinder Head Gasket And Alignment Pins
    GM470992Courtesy of GENERAL MOTORS CORP.
  13. Remove and discard the cylinder head gasket.
  14. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection in Engine Mechanical - 8.1L Unit Repair.
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