Cylinder Head & Manifolds: Removal
- Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Ensure negative battery cable is disconnected. Drain cooling system. Disconnect control cables, vacuum hoses, coolant hoses and electrical connectors at throttle body.
- Remove air cleaner assembly with air intake hose. Disconnect necessary electrical connectors, coolant hoses, fuel lines and vacuum hoses for cylinder head removal. Disconnect PCV hose.
- Remove power steering pump (if equipped) with hoses attached and secure aside. Remove power steering pump mounting bracket. On models equipped with A/C without power steering, remove A/C idler pulley (if equipped).
- Disconnect spark plug wires and ignition coils from spark plugs. Remove retaining bolt and camshaft position sensor with "O" ring from cylinder head. Camshaft position sensor is located on flywheel/drive plate end of cylinder head, just below the valve cover. See Fig 1.
- Remove bolts and EGR Vacuum Switching Valve (VSV). The EGR VSV is located on rear of cylinder head, just below valve cover. See Fig 1.
- Remove bolts/nuts, EGR pipe, EGR valve, gaskets and EGR valve vacuum modulator. See Fig 1.
- Remove bolts/nuts and coolant housing from rear of cylinder head. See Fig 1. Raise and support vehicle. Remove right lower engine cover.
- Remove exhaust pipe-to-cylinder block support bracket bolts (if equipped). Remove bolts/nuts and separate exhaust pipe from exhaust manifold. Remove bolts/nuts, exhaust manifold heat insulator, exhaust manifold and gasket.
- Remove bolts/nuts, throttle body and gasket from intake manifold. Remove bolt/nuts and intake manifold braces. Disconnect vacuum hose from fuel pressure regulator, located at end of delivery pipe.CAUTION: DO NOT allow fuel injectors to fall from delivery pipe when removing delivery pipe.NOTE: Spacers are installed between delivery pipe and cylinder head. Note direction of spacer installation for reassembly reference. Note location of electrical connectors on fuel injectors for reassembly reference.
- Disconnect fuel lines from delivery pipe and electrical connectors from fuel injectors. Remove delivery pipe-to-cylinder head bolts. Remove delivery pipe with fuel injectors, 2 spacers and 4 insulators from cylinder head. See Fig 1.
- Remove bolts/nuts, intake manifold and gasket. Remove nuts, seal washers, valve cover and gasket. Remove bolts, No. 2 timing belt cover and gasket. See Figure.
- Remove generator drive belt. Remove No. 3 timing belt cover from No. 1 timing belt cover. See Figure.
- Rotate crankshaft clockwise (viewed from timing belt end of engine) so cylinder No. 1 is at TDC on compression stroke and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. Cylinder No. 1 is front cylinder at timing belt end of engine.
- With cylinder No. 1 at TDC on compression stroke, ensure timing mark on camshaft sprocket aligns with timing mark on camshaft bearing cap. See Fig 2. Timing mark on camshaft sprocket is indicated by 5E stamped near hole in camshaft sprocket. If timing mark is not aligned, rotate crankshaft clockwise one complete revolution (360 degrees).
CAUTION: Manufacture lists cylinder head servicing procedure with timing belt removed only from camshaft sprocket. DO NOT allow timing belt to disengage from crankshaft sprocket during cylinder servicing.
- Place tape around end of pry bar and place pry bar between No. 2 idler pulley and No. 1 idler pulley with shop towel placed over No. 2 idler pulley. See Fig 3. Loosen No. 1 idler pulley bolt. Move No. 1 idler away from timing belt as far as possible and tighten bolt. Remove timing belt from camshaft sprocket.
- Remove No. 2 idler pulley from front of cylinder head. Remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION.CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage.
- Loosen cylinder head bolts in sequence using several steps. See Fig 4. Remove cylinder head bolts, cylinder head and cylinder head gasket.