Cylinder Head: Disassembly

LH cylinder head 

1. Remove the bolts and the exhaust manifold heat shield.

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2. • Remove the nuts and the exhaust manifold.
   • Discard the nuts.
   • Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .

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3. Remove and discard the studs and the exhaust manifold gasket.

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4. Remove the timing chain guide pin.

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5. 1. Remove and discard the direct injection fuel rail mounting bolts.
   2. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
      NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

      Remove the direct injection fuel rail and the fuel injectors.

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6. Disconnect the fuel injector electrical connectors.

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7. Remove the fuel injectors from the fuel rail.

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8. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.

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9. • Remove and discard the fuel injector O-ring seals.
   • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

     Remove and discard the fuel injector support rings.

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10. NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
    • Pull the lower Teflon® seal away from the injector.
    • Carefully cut and discard the lower fuel injector Teflon® seals.

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    RH cylinder head 

11. Remove the bolts and the exhaust manifold heat shield.

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12. • Remove the nuts and the exhaust manifold.
    • Discard the nuts.
    • Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .

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13. Remove and discard the studs and the exhaust manifold gasket.

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14. Remove the timing chain tensioner arm guide pin.

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15. Remove and discard the CHT sensor.

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16. 1. Remove and discard the direct injection fuel rail mounting bolts.
    2. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
       NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

       Remove the direct injection fuel rail and the fuel injectors.

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17. Disconnect the fuel injector electrical connectors.

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18. Remove the fuel injectors from the fuel rail.

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19. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.

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20. • Remove and discard the fuel injector O-ring seals.
    • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

      Remove and discard the fuel injector support rings.

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21. NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
    • Pull the lower Teflon® seal away from the injector.
    • Carefully cut and discard the lower fuel injector Teflon® seals.

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    All cylinder heads 

    NOTE: LH shown above, RH similar.
22. NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur.

    Using the special tools, remove the fuel injectors that remained in the cylinder head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

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23. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
    NOTE: Do not use compressed air to clean the tip of the fuel injector.
    NOTE: Do not use a brush to clean the tip of the fuel injector.

    Using the special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

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24. NOTE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure that the engine is warm (hand touch after cooling down) prior to spark plug removal.
    NOTE: If a spark plug is dropped, internal damage may result and the spark plug must be discarded. The use of a damaged spark plug may cause cylinder misfire resulting in engine damage
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the spark plugs.

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25. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

    Using the special tools, remove the valve collet, valve spring retainer and the valve spring. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor., 303-350 (T89P-6565-A) Compressor, Valve Spring., 303-1249 Valve Spring Compressor.

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26. NOTE: Use valve stem seal pliers (such as BeTooll HW0107 or equivalent).
    • Use commercially available valve stem seal pliers to remove the valve stem seal.
    • Discard the valve stem seal.

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27. Remove the valve.

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28. Repeat the previous 3 steps for each valve.