Cylinder Head and Head Gasket Removal — 8V Engines

Tools

• Jack stands or ramps
• 6 mm Allen head socket or 6 mm hex key
• Metric socket set
• Metric wrench set
• Flywheel Lock P9206 (optional)
• Pry bar
• Flat-tip screwdriver

Other Procedures Needed

• ENG-13: Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1
• FUEL-02: Fuel Injector and Fuel Rail Removal and Installation
• FUEL-09: Intake Manifold Removal and Installation
• CAM-01: Camshaft Assembly Removal
• COOL-02: Coolant System Draining, Filling, and Venting

Procedure

1. Place the car on jack stands or ramps.

2. Using ENG-13, set the engine to TDC.

3. Using FUEL-02, remove the fuel rail and fuel injectors.

4. Using FUEL-09, remove the intake manifold.

5. Using CAM-01, remove the camshaft assembly.

6. Using COOL-02, drain the cooling system.

7. Remove the exhaust manifolds as follows: a. Disconnect the header where it connects to the remainder of the exhaust system. b. Remove the exhaust manifold studs at the exhaust ports on the cylinder head. To remove a stud: loosen the retaining nut slightly, install a second (jam) nut on the stud, hold the inner nut with a wrench and tighten the outer nut firmly against it, then use a wrench on the inner nut and turn counterclockwise to back the stud out. Alternatively, remove the retaining nut and use a stud extractor that does not damage the stud threads.

   Note: Exhaust manifold studs are M8 and normally use 13 mm retaining nuts. M8 copper nuts (12 mm on the flats) are also available and offer better corrosion resistance; because they are smaller across the flats, a 13 mm socket can fit over a copper jam nut and onto the factory 13 mm nut beneath it.

   Note: On some cars it may be possible to remove the head with the exhaust manifolds still attached, saving disassembly time. Success depends largely on engine mount condition — newer mounts hold the engine higher in the engine compartment, making exhaust manifold clearance easier. If the manifolds will not clear the head studs, remove the bottom nut from the engine mount on the exhaust side and jack that side of the engine until the manifolds clear.

   c. Once all exhaust manifold studs are removed, remove the exhaust manifolds from the car.

8. Disconnect the coolant hose at the front of the cylinder head.

9. Disconnect the hose at the back of the cylinder head going to the heater control valve.

10. Using a 6 mm Allen head socket, remove the two Allen head bolts at the front of the cylinder head.

11. Remove the cylinder head retaining nuts. Loosen the head nuts crosswise, working from outside to inside.

12. Lift the cylinder head to remove. Tabs at the front and rear of the head are provided as pry points. If needed, use a pry bar underneath the tabs to break the head free of the gasket.