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Removal - Cylinder Head

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable.
  2. Remove engine cover and bracket. Refer to ENGINE COVER .
  3. Drain cooling system. Refer to STANDARD PROCEDURE .
  4. Evacuate A/C.
  5. Remove radiator core support.
  6. Remove cooling fan and fan drive viscous clutch assembly. Refer to RADIATOR - FAN - VISCOUS .
  7. Remove accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .
  8. Remove accessory drive belt tensioner and both idler pulleys, Idler pulley bolts are L.H. thread. (Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL) .
  9. Remove power steering pump pulley.
  10. Remove front engine lift bracket.
  11. Remove cooling fan support (Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL) .
  12. Remove generator and support bracketing (Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL) .
  13. Remove viscous heater.
  14. Rotate the engine to 90 degrees ATDC, or the 3 o'clock position at the crankshaft hub (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  15. Remove vibration damper.
  16. Disconnect main engine wiring harness connectors from right inner wheel housing.
  17. Disconnect main engine wiring harness ancillary components and set harness aside.
  18. Remove air cleaner housing.
  19. Remove exhaust manifold heat shield. See Fig 1.
    Fig 1: THERMOSTAT HOUSING
    GC0025182Courtesy of DAIMLERCHRYSLER CORP.
    1 - THERMOSTAT HOUSING GASKET
    2 - THERMOSTAT HOUSING
    3 - TURBOCHARGER OIL SUPPLY LINE BANJO BOLT
    4 - THERMOSTAT HOUSING RETAINING BOLTS
    5 - BRASS WASHER
    6 - EXHAUST MANIFOLD GASKET
    7 - EXHAUST MANIFOLD
    8 - EXHAUST MANIFOLD HEATSHIELD
    9 - EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS
    10 - OIL RETURN HOSE
    11 - HOSE CLAMPS
    12 - EXHAUST MANIFOLD RETAINING NUTS
    13 - TURBOCHARGER DOWNPIPE STUDS
    14 - TURBOCHARGER DOWN PIPE GASKET
    15 - TURBOCHARGER DOWNPIPE
    16 - TURBOCHARGER DOWNPIPE RETAINING NUT
  20. Remove turbocharger heat shield retaining bolt and position shield aside. See Fig 3.
  21. Remove turbocharger oil supply line from turbocharger. See Fig 3.
  22. Raise and support vehicle.
  23. Disconnect exhaust stabilizer bracket at lower exhaust manifold. See Fig 3.
  24. Disconnect exhaust system bracket at transmission crossmember.
  25. Lower the vehicle and remove the exhaust manifold retaining nuts.
  26. Slide the exhaust manifold and turbocharger off of exhaust manifold studs. See Fig 3.
  27. Remove coolant hoses at thermostat housing.
  28. Disconnect fuel return hose from fuel injectors and set aside (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL) .
  29. Remove fuel injector pressure lines (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL) .
  30. Disconnect fuel pump high pressure line at fuel rail (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL) .
  31. Disconnect oil level indicator tube from intake manifold.
  32. Disconnect brake booster line bracket from intake manifold and position aside.
  33. Remove fuel injectors (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL) .
    CAUTION: Before removing the cylinder head cover/intake manifold or timing belt the crankshaft hub must placed at 90° ATDC or the 3 O'clock position. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  34. Remove timing belt outer cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL) .
  35. Remove timing belt (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) .
  36. Using VM.1085, remove both camshaft gears. See Fig 2.
    Fig 2: VM.1085 CAMSHAFT LOCKING TOOL
    GC0026125Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove timing belt inner cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL) .
  38. Remove cylinder head cover/intake manifold (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) .
  39. Remove rocker arm and lifter assemblies from cylinder head. Be sure to keep in same order as removed. 
    Fig 3: CYLINDER HEAD ASSEMBLY
    GC0025179Courtesy of DAIMLERCHRYSLER CORP.
    1 - CYLINDER HEAD BOLT
    2 - GLOW PLUG
    3 - COOLANT FITTING
    4 - CYLINDER HEAD ALIGNMENT DOWEL
    5 - GLOW PLUG HARNESS
    6 - CYLINDER LINER
    7 - CYLINDER BLOCK
    8 - CYLINDER HEAD GASKET
    9 - CYLINDER HEAD
    10 - ROCKER ARM ASSEMBLIES
  40. Remove cylinder head cover/intake manifold gasket from cylinder head.
  41. Disconnect glow plug and engine coolant temperature electrical connectors.
  42. Remove turbocharger outlet to charge air cooler hose.
  43. Remove cylinder head bolts.
  44. Remove cylinder head assembly from engine block. See Fig 3.
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