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Home >> Saturn >> 2006 >> Vue Red Line, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
    2. Fig 1: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Loosen the clamp at the air cleaner assembly.
  4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
  5. Loosen the clamp at the throttle body assembly.
  6. Disconnect the positive crankcase ventilation (PCV) fresh air vent hose at the cam cover.
  7. Remove outlet resonator/duct assembly.
  8. Remove the air cleaner assembly hold-down bolt.
  9. Remove the air cleaner assembly.
    10. Fig 2: View of Ignition Module Housing Assembly With Spark Plug Boots
    GM951506Courtesy of GENERAL MOTORS CORP.
  10. Remove the ignition module bolts.
  11. Remove the ignition module assembly.
    12. Fig 3: Removing/Installing ECM Assembly & Bolts
    GM947702Courtesy of GENERAL MOTORS CORP.
  12. Disconnect engine control module (ECM) electrical connector and ground at ECM.
  13. Remove oil level indicator bolt to manifold.
  14. Disconnect the electrical connector at the throttle body.
  15. Disconnect the electrical connector at the fuel injector harness and the attachment at bottom of the intake manifold.
  16. Disconnect the electrical connector at purge solenoid and manifold absolute pressure (MAP) sensor.
  17. Disconnect the vacuum hose at the brake booster.
    18. Fig 4: View Of Water Pipe Support Bracket
    GM856306Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the coolant pipe bracket bolts to front of cylinder head.
    19. Fig 5: Disconnecting/Connecting Ground Strap On The Camshaft Cover Assembly
    GM895199Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the degas hose at clamp at the cylinder head and unclip from the fuel rail. Position away from the cam cover assembly.
  20. Disconnect ground strap at rear of the cam cover assembly.
    21. Fig 6: View Of Fuel System Pressure Tester
    GM854376Courtesy of GENERAL MOTORS CORP.
  21. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 2.2L (L61).
  22. Disconnect the SA9127E  after pressure has been relieved. See Special Tools .
    23. Fig 7: View Of Fuel Feed Pipe Fastener
    GM854304Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the fuel rail bracket and bolt at the rear cam cover.
    24. Fig 8: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
    CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the 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 the transfer line fitting at the fuel rail.
    25. Fig 9: Removing/Installing Cam Cover Assembly
    GM894940Courtesy of GENERAL MOTORS CORP.
  25. Position the fuel line away from the cam cover assembly.
  26. Remove the cam cover assembly bolts.
  27. Remove the cam cover assembly.
    28. NOTE: To avoid valve piston contact, No. 1 cylinder piston must be positioned at approximately 60 degrees before-top dead center (BTDC). Pistons are properly positioned when the diamond shaped hole on the intake camshaft sprocket is located at 12 o'clock.
    IMPORTANT: To rotate camshafts, use a 24 mm open-end wrench on camshaft flats. Camshafts should be rotated in a clockwise direction only, facing camshaft sprockets from passenger side of vehicle.
    Fig 10: Locating No. 1 Piston To 60 Degrees Before Top Dead Center
    GM951992Courtesy of GENERAL MOTORS CORP.
  28. Locate the No.1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.
    29. Fig 11: Removing/Installing Upper Timing Chain Guide
    GM894944Courtesy of GENERAL MOTORS CORP.
  29. Remove upper timing chain guide.
    30. Fig 12: Removing/Installing Timing Chain Tensioner Assembly
    GM894951Courtesy 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 the timing chain tensioner.
    31. Fig 13: Fixed Timing Chain Guide Access Plug
    GM894968Courtesy of GENERAL MOTORS CORP.
  31. Remove the fixed timing chain guide access plug.
  32. Using a magnetic socket, remove the upper fixed guide bolt.
    33. Fig 14: Installing SA9105E Set Up For SUV Application
    GM952023Courtesy of GENERAL MOTORS CORP.
  33. Install SA9105E  set up for SUV application. See Special Tools . Also, use J 45122 with long hooks from J 43405  . See Special Tools . Refer to Engine Support Fixture .
    34. Fig 15: View Of RH Engine Mount
    GM928650Courtesy of GENERAL MOTORS CORP.
  34. Remove the right-hand engine mount-to-bracket bolts.
  35. Remove the right-hand mount assembly nuts.
  36. Remove the right-hand engine mount assembly.
    37. Fig 16: Removing/Installing Right Hand Engine Mount Bracket
    GM928024Courtesy of GENERAL MOTORS CORP.
  37. Remove the right-hand mount bracket.
  38. Remove the right-hand engine mount bracket.
  39. Raise the vehicle on hoist.
  40. Remove the right wheel and splash shield.
  41. Remove J 44811  . See Special Tools .
  42. Remove the accessory drive belt.
  43. Remove the tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.
    44. Fig 17: Removing & Installing Belt Tensioner Bolt
    GM894941Courtesy of GENERAL MOTORS CORP.
  44. Remove the tensioner assembly.
    45. Fig 18: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
    GM895194Courtesy of GENERAL MOTORS CORP.
  45. Install J 38122-A  . See Special Tools .
    46. Fig 19: Removing & Installing Damper Assembly
    GM895197Courtesy 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 threw-jay puller.
  46. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.
    47. Fig 20: Removing/Installing Front Cover Assembly
    GM895054Courtesy of GENERAL MOTORS CORP.
    NOTE: To avoid damage to the front cover assembly, do not pry against the cover.
  47. Remove the front cover assembly bolts.
  48. Remove the lower water pump assembly bolt.
  49. Remove the front cover assembly and gasket.
    50. Fig 21: View Of Drain Valve
    GM931332Courtesy of GENERAL MOTORS CORP.
  50. Drain the coolant system. Refer to Draining and Filling Cooling System (GE 47716 Fill) or Draining and Filling Cooling System (Static Fill) in Engine Cooling.
    51. Fig 22: View Of Exhaust Manifold Pipe & Manifold
    GM892082Courtesy of GENERAL MOTORS CORP.
  51. Remove the exhaust manifold pipe to the manifold nuts.
  52. Disconnect the electrical connectors at the front and rear oxygen sensors.
  53. Remove down pipe to intermediate pipe nuts.
  54. Remove down pipe assembly.
  55. Lower the vehicle.
    56. Fig 23: View Of Radiator Inlet Hose Clamp
    GM931402Courtesy of GENERAL MOTORS CORP.
  56. Remove the upper radiator hose from cylinder head.
    57. Fig 24: Removing/Installing Exhaust Camshaft Sprocket
    GM894960Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY) bolt, and must be discarded to prevent premature failure.
  57. Use a 24 mm wrench to hold the camshaft assembly while removing the exhaust sprocket bolt. Discard the bolt.
  58. Remove the exhaust sprocket.
    59. Fig 25: Timing Chain Adjustable Guide And Bolt
    GM894967Courtesy of GENERAL MOTORS CORP.
  59. Remove the adjustable guide through the top of the cylinder head.
    60. Fig 26: View Of Fixed Timing Chain Guide
    GM412165Courtesy of GENERAL MOTORS CORP.
  60. Remove the fixed timing chain guide.
    61. Fig 27: Holding Camshaft Assembly Using 24 mm Wrench
    GM895205Courtesy of GENERAL MOTORS CORP.
  61. Use a 24 mm wrench to hold the camshaft assembly while removing the intake sprocket bolt. Discard the bolt.
  62. Remove the intake sprocket.
  63. Remove the timing chain assembly through top of cylinder head.
  64. Remove the timing chain drive sprocket from the crankshaft.
    65. Fig 28: Removing & Installing Timing Chain Oiling Nozzle
    GM895210Courtesy of GENERAL MOTORS CORP.
  65. Remove the timing chain oiling nozzle and remove any debris from hole in block.
    66. Fig 29: Exploded View Of Timing Chain & Components
    GM895127Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Replace timing chain guides if wear exceeds 1.12 mm (0.045 in).
  66. Inspect timing chain guide for wear.
  67. Inspect the timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on the chain.
    68. Fig 30: Installing SA9105E Set Up For SUV Application
    GM952023Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not raise the vehicle without the right hand mount or the engine support fixture attached. Bodily harm or engine mount damage may occur.
  68. Install floor jack with block of wood and support the engine at the center of the oil pan.
  69. Remove engine three bar engine support fixture to allow cylinder head to be removed.
    70. Fig 31: Cylinder Head Bolts Loosening Sequence
    GM895538Courtesy of GENERAL MOTORS CORP.
  70. Remove cylinder head bolts using loosening sequence.
  71. With assistance, remove the cylinder head from block with the exhaust and intake manifold attached.
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