For 1990-2009 cars

## Cylinder Head Removal SOHC

#### Tools Required

• | J 43914 Universal Clamp Pliers

• | SA9104E Front Crank Seal Replacer

• | SA9123E Gasket Seal Cutter

• | SA9127E Gage Bar Set

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Disconnect the cable from the negative terminal of the battery and remove the coolant bottle cap.

Notice: The engine's cooling system thermostat and water pump will not function correctly if oil is found in the cooling system. The cooling system must be flushed and the water pump and the thermostat's cartridge replaced.

2. Drain the coolant from the radiator and engine. The engine drain is at the right front corner of the engine block under the thermostat housing.
3. Remove the air cleaner cover assembly and air inlet duct and resonator.

Disconnect the rocker cover fresh air hose at the rocker cover.

Important: The throttle body assembly, fuel rail, pressure regulator, injectors and intake manifold can be removed with cylinder head assembly from vehicle.

4. Disconnect accelerator cable from throttle body and intake manifold bracket.

Important: Use long noise pliers to remove the coolant temperature connector.

5. Remove the following electrical connectors:

• | Coolant temperature gage

• | Injector connectors

• | Idle air control (IAC) valve

• | Throttle position (TP) sensor

• | Manifold air pressure (MAP)

• | Remove oxygen sensor

• | Remove spark wires

• | Air conditioner compressor

• | EGR solenoid

6. Lay the harness over onto the underhood fuse block and battery cover.
7. Disconnect the following vacuum hoses:

• | EVAP canister purge valve

• | PCV hose at cam cover

• | Throttle body connector

• | Vacuum brake booster hose at brake booster

Important: The MAP sensor does not require removal.

Important: Use the J 43914 to remove hose clamps.

8. Disconnect the following hoses:

• | Upper radiator hose at cylinder head outlet

• | Deaeration hose at intake manifold

• | Heater hose at intake manifold or front of dash

Caution: Catch leaking fuel in a container whenever fittings are loosened or lines are disconnected.

9. Disconnect the fuel line:
10. Connect the SA9127E to fuel pressure test port.
11. Install bleed hose into an approved container and open valve to bleed system pressure. Once pressure is bled, remove gage from fuel pressure test port and recap test port.
12. Remove the nut at the fuel line clip below the fuel pressure test port. Open the hinged clip and separate the fuel supply line and the fuel return line from the clip.

Notice: Failure to open the clip could result in kinking of the fuel lines when connections at the fuel rail are disconnected.

13. Disconnect the fuel supply line by compressing the 2 plastic retainer tabs and pulling on the fuel supply line. Remove and discard the plastic retainer.
14. Remove the three right-hand upper engine torque axis mount-to-front cover nuts and the two mount to midrail bracket nuts, allowing the powertrain to rest on the block or wood. Remove the mount.

Important: The accessory drive belt idler pulley must be removed to allow the front cover to be removed and replaced in the vehicle.

15. Remove the accessory drive belt and tensioner. It is not necessary to remove the water pump pulley.

Notice: Cover the valve train area whenever repairs are not being performed to prevent foreign debris from entering the engine.

16. Remove the rocker cover.

Important: Inspect the two rocker cover silicone insulators for cracks. Replace isolators if deterioration exist.

17. Disconnect the deaeration line at cylinder head water outlet and from support bracket.

Important:

• | The rear compressor bracket center hole is slotted for ease of compressor removal and installation.

• | It is not necessary to discharge the A/C system.

18. Remove the three A/C compressor front bracket bolts (if equipped) attached to cylinder head and block. The rear bracket bolts can be removed from the compressor or bracket attachment to block and head.

Tie the compressor assembly to the vehicle front support bar.

Important: It is not necessary to remove the water pump pulley.

19. Remove the three power steering pump bracket attachment bolts (if equipped) and position the pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold. Refer to "Engine Drive Belt and Accessories" section.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

20. Jack or raise the vehicle on a hoist.
21. Drain the engine oil.
22. Remove the right front wheel and splash shield.
23. Remove the accessory drive belt tensioner.
24. Remove front crankshaft pulley. Hold pulley with a strap wrench or use a 3/4 inch square x 12 inch long piece of wood wedged between the pulley spoke and rear, lower side of front cover when removing the bolt.

Important: Puller jaw slots are cast into pulley for removal with a small three jaw puller, if required.

25. Disconnect front exhaust pipe from exhaust manifold and discard gasket.

Important: Remove the three nuts from exhaust manifold.

26. Remove the front cover assembly:

Important: Install service tool SA9104E with flat side toward sprocket. Failure to hold the crankshaft timing sprocket in place will cause timing chain guide damage. This tool also aligns the oil pump gerotor during front cover installation. After the front cover assembly is loosened and moved approximately 25.4 mm (1 in) from the engine, the crankshaft timing gear service tool should be removed.

27. Install the SA9104E to make sure the front crankshaft sprocket is held firmly in place.

Notice: Spray the two dowel pin holes in the front cover with penetrating oil to prevent cover damage during removal.

28. Remove the four front oil pan bolts.
29. Use the SA9123E to cut the oil pan seal away from the front cover.
30. Remove the front cover bolts.

Important: The front cover assembly can be removed from under the hood or through the wheel well.

Important: Cover the front of the engine with a shop towel to prevent debris entry into the oil gallery holes and pan.

31. Using a screwdriver, pry the front cover away from the cylinder block, using the pry locations shown.

Important: Positioning crankshaft 90 degree off top dead center (TDC) to make sure piston will not contact valves upon assembly.

32. Rotate crankshaft clockwise (viewed from crankshaft accessory belt end) so timing mark on crankshaft sprocket and key way align with main bearing cap split line.
33. Remove timing chain, tensioner, guides, camshaft sprocket, and chain. Use a 21 mm (7/8 in) wrench to hold the camshaft when removing the sprocket bolt.

Notice: Head warpage or cracking could result from removing the bolts out of order or when the cylinder head is hot.

Notice: Only use a six point socket to remove the cylinder head bolts. A 12 point socket will round off the bolt heads.

34. Use a six point socket to remove the cylinder head bolts.
35. Uniformly loosen and remove the 10 head bolts in several passes, in the sequence shown

Notice: Be careful not to damage the aluminum the aluminum cylinder head and block gasket sealing surfaces when removing the cylinder head or during cleaning.

36. Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks or a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block bosses.

## Cylinder Head Removal DOHC

#### Tools Required

• | J 43223 Rocker Arm Removal Tool

• | J 43299 Camshaft Holder

• | SA9104E Front Crank Seal Replacer

• | SA9123E Gasket Seal Cutter

• | SA9124E Valve Spring Compressor/Remover

• | SA9127E Gage Bar Kit

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Important: Camshafts can be removed using theJ 43299 . The SA9127E is used for pressurizing the cylinder with 690 kPa (100 psi) of air to hold the valves closed. Valve springs, caps and stem seals can be replaced without removing the cylinder head using the SA9124E . Rocker arm assemblies can be removed using theJ 43223 . Refer to Camshaft and Lifter Replacement and Valve Spring and Stem Seal Replacement In-Vehicle at the end of this section.

1. Disconnect cable from negative terminal of battery and remove coolant bottle cap.

Notice: The engine's cooling system thermostat and water pump will not function correctly if oil is found in the cooling system. The cooling system must be flushed and the water pump and the thermostat's cartridge replaced.

2. Drain coolant from radiator and engine. Engine drain is at right front corner of engine block under thermostat housing.
3. Remove air cleaner cover assembly and air inlet duct.

Disconnect the cam cover air hose at air duct.

Important: The throttle body assembly, fuel rail, injectors and intake manifold can be removed with cylinder head assembly from vehicle.

4. Disconnect accelerator cable from throttle body and intake manifold bracket.

Important: Use long nose pliers to remove the coolant temperature connectors.

5. Remove the following electrical connectors:

• | Injector connector

• | Idle air control (IAC) valve

• | Throttle position (TP) sensor

• | Manifold air pressure (MAP)

• | Remove oxygen sensor

• | Remove spark wires

• | Air conditioner compressor

6. Remove the EGR connector.
7. Lay harness over onto underhood fuse block and battery cover.

Important: The MAP sensor does not require removal.

8. Disconnect the following vacuum hoses:

• | EVAP canister purge valve

• | PCV hose at cam cover

• | Throttle body connector

• | Vacuum brake booster hose at brake booster.

Important: The MAP sensor does not require removal.

9. Disconnect the following hoses:

• | Upper radiator hose at cylinder head outlet.

• | Deaeration hose at intake manifold.

• | Heater hose at intake manifold or front of dash.

Caution: Catch leaking fuel in a container whenever fittings are loosened or lines are disconnected.

10. Disconnect fuel line:

• | Remove attachment bolt that clamps fuel lines to the intake manifold support brace.

• | Disconnect the fuel supply line to the fuel rail.

• | Remove power steering support bracket.

Important: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.

11. Unclip the lower splash shield attachments and place a 1 inch x 1 inch x 2 inch long bock of wood between the torque strut and frame.
12. Remove the three right-hand, upper engine torque axis mount to front cover nuts and the two mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood.

Important: The accessory drive belt idler pulley must be removed to allow the front cover to be removed and replaced in the vehicle.

13. Remove the accessory drive belt and tensioner. It is not necessary to remove the water pump pulley.

Important: Cover camshaft area whenever repairs are not being performed to prevent foreign debris from entering engine.

Important: Inspect the 8 cam cover silicone isolators for cracks. Replace the isolators if deterioration exists.

14. Remove camshaft cover assembly.

Important: It is not necessary to remove the water pump pulley.

15. Remove the five power steering pump bracket attachment bolts (if equipped) and position the pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold. Refer to Engine Drive Belt and Accessories section.

Important: The rear compressor bracket center hole is slotted for ease of compressor removal and installation.

Important: It is not necessary to discharge the A/C system.

16. Remove the three A/C compressor front bracket bolts (if equipped) attached to cylinder head and block. The rear bracket bolts can be removed from the compressor or bracket attachment to block and head.

Tie the compressor assembly to the vehicle front support bar.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

17. Jack or raise the vehicle on a hoist.
18. Drain the engine oil.
19. Remove the right wheel and splash shield.
20. Remove the intake manifold support brace bolt attached to the intake manifold located next to the generator.
21. Remove front damper/pulley assembly. Hold damper with a strap wrench or use a 3/4 inch square x 12 inch long piece of wood wedged between the damper spoke and rear, lower side of front cover when removing the bolt.

Puller jaw slots are cast into damper/pulley assembly for removal with a small three jaw puller if required.

22. Disconnect exhaust pipe from exhaust manifold:

Remove the three nuts from the flange.

23. Removal of the front cover assembly:

Important: Install the SA9104E with flat side toward the sprocket. Failure to hold the crankshaft timing sprocket in place will cause timing chain guide damage. This tool also aligns the oil pump gerotor during front cover installation. After the front cover assembly is loosened and moved approximately 25.4 mm (1 in) from the engine, the crankshaft timing gear service tool should be removed.

24. Install the SA9104E to make sure the front crankshaft timing sprocket is held firmly in place.
25. Remove the 4 front oil pan bolts.
26. Use RTV SA9123E to cut the oil pan seal away from front cover.
27. Spray the 2 dowel pin holes, upper left-hand and lower right-hand side of cover, in the cover with penetrating oil to facilitate cover removal off the dowel pins.

Important: One front cover assembly attachment bolt is located under the torque axis mount flange, above the accessory drive belt pulley.

28. Remove the front cover bolts.

Important: The front cover assembly can be removed from under the hood or through the wheel well.

Important: Cover the front of the engine with a shop towel to prevent debris entry into oil gallery openings and pan.

29. Using a screwdriver, pry the front cover away from the cylinder block using the pry locations tabs provided.

Important: Position crankshaft 90 degrees off the top dead center to make sure pistons will not contact valves upon assembly.

30. Rotate crankshaft clockwise (viewed from crankshaft accessory belt end) so timing mark on crankshaft sprocket and key way align with main bearing cap split line.

Caution: The camshafts can rotate during timing chain and sprocket removal. Do not place fingers or tools between the camshaft sprocket and chain during removal or assembly.

31. Remove timing chain tensioner, guides, camshaft sprockets and chain. Use a 24 mm wrench to hold the camshaft when removing the sprocket bolts.

Important: Camshaft bearing caps are marked for proper installation.

32. Uniformly remove camshaft bearing cap attachment bolts and caps.
33. Remove each camshaft.
34. Remove lash adjuster and rocker arms. Keep them in order.

Notice: Only use a six point socket to remove the cylinder head bolts. A 12 point socket will round off the bolt heads.

35. Use a six point socket to remove the cylinder head bolts.

Important: Head warpage or cracking could result from removing the bolts out of order or when cylinder is hot.

36. Uniformly loosen and remove the 10 head bolts in several passes, in the sequence shown.

Notice: Be careful not to damage the aluminum the aluminum cylinder head and block gasket sealing surfaces when removing the cylinder head or during cleaning.

37. Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks or a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block bosses.