Cannt remove cyclinder head

Part 1 of 3: Getting to the head bolts

Materials Needed

• Eye protection
• Gloves
• Oil and coolant drain
• Parts cleaner or brake cleaner
• Shop rags
• Socket set and ratchet1: Drain the oil and coolant. Put on your eye protection and gloves and drain the oilfrom the vehicle.
  Make sure the vehicle can not be started by removing the negative cable from the battery. Next the coolant will need to be drained so it does not leak when the head bolts are loosened.
  Step 2: Clean valve cover. Use some of the parts cleaner or brake cleaner to clean up the valve cover and as much of the cylinder head as is reasonable.Remove valve cover. If necessary, remove other components to make the valve covers accessible, and start removing the bolts from the valve cover.
  Once all bolts are removed carefully removed the valve cover from the cylinder head. If any valve cover gasket material remains, remove it at this time and clean any excess oil from the edges. Set the valve cover aside carefully as it will be reused with a new gasket once repairs are completed.

  Part 2 of 3: Pushrod engine head bolt removal

  Materials Needed
  
  • Head bolt socket (if needed)
  • Numbered cardboard
  • Rubber hammer
  • Socket set and ratchetStep 1: Rocker arm and rocker removal. A pushrod engine has long pushrods that protrude through the cylinder head and attach to the rocker rail.
    The rocket arm will need to be loosened first. Many manufactures have a specific sequence for removal of the rocker arm bolts. After the rocker arm is removed, the rockers will be unbolted.
    Set all rocker arms aside in the order they were removed as they should go back to the cylinder they were removed from.Step 2: Remove the pushrods. Remove the pushrods one at a time from the cylinder head.
    Put them into a numbered piece of cardboard as the pushrods will go back into the same slot they came from.Step 3: Loosen head bolts. Use the ratchet begin to break the cylinder head bolts loose.
    Each bolt will be loosened but not removed. Loosen all of the bolts before removing any of the the bolts all the way.
    Step 4: Remove the bolts. Place each bolt through a numbered hole in the cardboard in case the head bolts are different lengths so they can be installed back into the proper hole.
    The bolts may require a special socket depending on the manufacture.
    Step 5: Lift off the cylinder head. Once all bolts are removed, lift up on the cylinder headgently; the head should come free easilyIf the cylinder head sticks, lightly use a dead blow or rubber mallet to tap the cylinder head to be able to remove it. Set to the side in a safe area.
    
    • Warning: Cylinder head bolts have a specific sequence that is used when removing them. Consult the manufacturer's specifications for the proper removal sequence for the engine being worked on.

    Part 3 of 3: Overhead cam head bolt removal

    Material Needed
    
    • Socket set and ratchetStep 1: Remove the timing cover. The timing cover will need to be removed to gain access to the timing belt or chain.
      This is necessary because the cam shaft sits in the cylinder head and is attached to the crankshaft with either a timing belt or timing chain.
      Step 2: Time the engine to remove the belt. The engine will need to be timed to avoid damage when the timing belt is removed.
      Each engine is different and will have its own procedures to time. There should be marks on the camshaft and crankshaft that will be aligned to set the timing at top dead center (TDC)Step 3: Remove the timing belt. The timing belt tensioner will be removed or released to take the tension off the belt.
      Once the belt is loosened, it should be able to be slipped of the camshaft in the cylinder head.Step 4: Remove the head bolts. Every engine will have its own procedures for the order that the head bolts are removed or tightened.
      Loosen head bolts ¼ turn each in the order specified, which may require a special socket. Once all the bolts have been loosened they may be removed one at a time. The bolts must be organized or marked in case they are different lengths.
      Step 5: Remove the cylinder head. Once all the bolts are removed, the cylinder head may be removed from the engine. If it is stuck, tap lightly on the side of the head with a rubber hammer to loosen the cylinder head.
      
      • Warning: Most head bolts are torque-to-yield. These head bolts are single use only and once removed must be replaced. Torque-to-yield head bolts stretch when they are torqued to allow them to tighten properly and repeated application can cause the head bolt to break.
      Removing the head bolts can seem like a daunting process

For the four cylinder engine:

1. Remove and label all electrical wiring, connectors and vacuum hoses necessary to gain removal clearance.
2. Remove the spark plug wires. Disconnect the PCV hose.
3. Remove the four nuts and grommets located on top of the cylinder head cover.

1. Remove the cylinder head cover and the cover gasket from the cylinder head.
2. Discard the gasket and replace with a new one.

To install:

1. With a wire brush or gasket scraper, remove all the old gasket material from the cylinder head and the cylinder head cover gasket surfaces.
2. When the cylinder head surfaces are free and clean, apply beads of sealant to the cylinder head in the locations shown in the accompanying illustrations.
3. Install the new cylinder head gasket in the cover. Make sure that the gasket seats evenly.
4. Place the cylinder head cover with the gasket onto the cylinder head.
5. Install the four grommets and nuts. Uniformly tighten the nuts in several passes to 17 ft. lbs. (23 Nm).
6. Connect the PCV hose. Connect all removed vacuum hoses, connectors and electrical wiring. Connect the negative battery cable.
7. Start the engine and inspect for oil leaks.
8. Repair any leaks as necessary.

For the V-6 (3.0L) engine:

1. Drain and recycle the engine coolant.
2. Disconnect the radiator inlet hose.
3. Disconnect the throttle and accelerator cables.
4. Remove the air cleaner cap assembly.
5. Remove the V-bank cover. Use a hexagon wrench to loosen the nuts.
6. Label and remove all emission control valve hoses. Disconnect any wiring interfering with the valve cover removal.
7. Remove the air intake chamber. This will gain you access to the back valve cover.
8. Disconnect the engine wire from the left hand side, No. 3 timing belt cover, rear side and right hand side. Most of the wiring is secured by nuts and or bolts to the body of the vehicle.
9. Remove the ignition coils, make sure the place them in order on a table so not to mix them up.
10. Remove the 8 bolts retaining the valve covers and gasket.
11. Clean the mating area of the valve cover and cylinder heads well. If necessary, scrape any left gasket from either surface.
12. Apply seal packing to the cylinder heads and place new gaskets into position.
13. Attach the valve covers. Uniformly tighten the bolts in several passes to 69 inch lbs. (8 Nm).
14. Install the spark plugs in their proper locations, then place the ignition coils into place and secure.
15. Attach all engine wiring be sure to secure each harness properly.
16. Install the air intake chamber. Refer to Fuel System .
17. Attach all emission hoses and wiring.
18. Attach the V-bank cover.

Rocker Arm (Valve) Cover REMOVAL & INSTALLATION 2.3L 4-Cylinder Engines

1. Disconnect the negative battery cable.
2. Label and remove the spark plug wires.
3. Remove the attaching bolts for the valve cover.
4. Remove the valve cover from the cylinder head. If necessary, lightly tap the valve cover with a soft hammer to aid in removal. To install:
   
5. Thoroughly clean the valve cover and cylinder head gasket mating surfaces.
6. Install the valve cover on the cylinder head using a new gasket.
7. Tighten the valve cover bolts to 14 ft. lbs. (20 Nm) in a crisscross pattern.
8. Install the spark plug wires.
9. Connect the negative battery cable.
10. Start the engine and check for leaks. Fig. 1: Valve cover and gasket assembly
    

2.8L 6-Cylinder Engine

1. Disconnect the negative battery cable.
2. The following steps are necessary if your car has A/C and if you are removing the passenger side valve cover, if you do not need to remove the passenger side valve cover, skip them.
   1. Remove the A/C compressor belt and the compressor from the mounting bracket located on the passenger side of the engine. Do not remove the lines from the compressor.
   2. Place the compressor with the lines attached on the passenger side front shock tower and secure.
   3. Remove the compressor bracket.
3. Remove the air cleaner-to-throttle body hose.
4. Label and remove all necessary electrical and vacuum connections.
5. Remove the attaching bolts for the valve cover(s).
6. Remove the valve cover(s) from the cylinder head(s). If necessary, lightly tap the valve cover with a soft hammer to aid in removal. To install:
   
7. Thoroughly clean the valve cover(s) and cylinder head gasket mating surfaces.
8. Install the valve cover(s) on the cylinder head(s) using new gaskets.
9. Tighten the valve cover bolts to 11 ft. lbs. (15 Nm) in a crisscross pattern.
10. Install all necessary electrical and vacuum connections.
11. Install the air cleaner assembly.
12. Install the A/C bracket (if removed).
13. Install the A/C compressor and belt (if removed).
14. Connect the negative battery cable.
15. Start the engine and check for leaks.

2.3L and 2.4L 5-Cylinder, and 2.9L 6-Cylinder Engines The 2.3L and 2.4L 5-cylinder, and 2.9L 6-cylinder engines have a two-piece cylinder head, the upper half and the lower half. The upper half is basically the same as a valve cover, except that it incorporates the bearing caps for the camshafts into the underside.

1. Disconnect the negative battery cable.
2. Remove the spark plug access cover.
3. Label and remove the ignition coils and vent hoses or the distributor cap and wires if equipped.
4. Check the cam alignment before removing the cylinder head.
5. Remove the bolts attaching the upper cylinder head.
6. Remove the upper cylinder head, lightly tap with a soft hammer if necessary. To install:
   
7. Thoroughly clean the upper and lower cylinder head gasket mating surfaces.
8. Apply liquid sealing compound to the upper cylinder head mating surface. WARNING
   Use a roller or your finger to spread sealant, do not use an excessive amount of sealant, or the oil passages could become clogged.
   
9. Place the upper cylinder head onto the lower cylinder head.
10. Check the cam alignment before tightening the cylinder head.
11. Install Volvo tool number 5454 or equivalent to the upper cylinder head.
12. Tighten the nut on the tools to seat the upper cylinder head.
13. Tighten the upper cylinder head bolts, beginning from the center out to 13 ft. lbs. (17 Nm).
14. Install the ignition coils and hoses or the distributor cap and wires.
15. Install the spark plug access cover.
16. Connect the negative battery cable.
17. Start the vehicle and check for leaks. Fig. 2: Remove the clamp and detach the vent hose
    Fig. 3: Remove the spark plug cover and the plug wires or ignition coils to access the retaining bolts
    Fig. 4: Remove the retaining bolts
    Fig. 5: A light tap with a soft-faced hammer is usually required to loosen the valve cover
    Fig. 6: Carefully lift the upper cylinder head up and off the lower section. Note the integral camshaft bearing caps in the casting
    

The covers come off the steering collum and the switch is heald to the collum with two #4torx headed bolts ( torx socket not a key ) unplug the electrical connector and plug in the new one It'll come with new bolts. sometimes they have #3 torx and you'll just have to cut the heads off and install the new bolts after the switch is out of the way. put the lock cyclinder back in. The lock cyclinder comes out of the old one as the cover is lifted up theres a pin to push down with the key in the run position, and the tumber will pull out and the cover can be removed as you put it back to gether the cullum can be all the way to gether and put the lock and key in last, then turn it to start then off and your done.

3.4L Engine To Remove:

1. Remove the lower intake manifold.
2. Remove the exhaust crossover pipe.
3. If removing the right cylinder head, remove the catalytic converter from exhaust manifold.
4. If removing the left cylinder head, remove the engine oil dipstick and tube.
5. Remove the rocker arms and pushrods.
6. Remove and discard the cylinder head bolts.
7. Remove the cylinder head.
8. Clean the mating surfaces on the following items:
   • Cylinder head
   • Cylinder block
   • Intake manifold
9. Clean the cylinder block bolt threads.

NOTE: During disassembly, keep the valve train components together for proper location during assembly.
To Install:
NOTE: Coat the cylinder head bolt threads using thread sealer.

1. If removed, install the following components:
   • Exhaust manifold
   • Accessory studs
   • Spark plugs
2. Place the cylinder head gasket in position over the dowel pins. Ensure that the THIS SIDE UP note is showing.
3. Install the cylinder head. Cylinder head torque sequence ’99-‘00
   
   Cylinder head torque sequence ’01-05
   
   
4. Install the new cylinder head bolts.
   • Tighten the cylinder head bolts a first pass to 44 ft lb (60 Nm).
5. Tighten the cylinder head bolts in sequence an additional 95 degrees.
6. Install the intake gasket.
7. Install the pushrods and rocker arms.
8. Raise and support the vehicle.
9. Install the catalytic converter and dipstick tube and indicator if removed.
10. Lower the vehicle.
11. Install the exhaust crossover pipe.
12. Install the intake manifolds.
13. Connect negative battery cable.
14. Fill the cooling system.

They are directly below the coil packs (10mm bolts).

you have to take the top part of the motor off to get to the head gasket. all the way down to the heads.

I used to make the heads that are in this car and own one myself. the spark plugs are located on the top of the cylinder heads. you will need to remove the valve cover to expose the spark plugs

Is there any sound when the key is turned? The solenoid may be stuck, and a light tap with a hammer may free it up. The starter is located on the engine block.

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REMOVAL & INSTALLATION
STARTER MOTOR
Removal & Installation (2.0L)

CAUTION:When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Before testing starter, ensure transmission is in Park or Neutral.

Disconnect negative battery cable. Remove air cleaner. Remove upper starter mounting bolts. Raise and support vehicle. Disconnect starter solenoid wire connections. Remove starter motor lower mounting bolt. Remove starter motor. To install, reverse removal procedure. Ensure negative battery cable is installed with starter mounting bolt. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (2.5L)

Disconnect negative battery cable. Remove air cleaner and air cleaner bracket. Disconnect starter solenoid wire connections. Remove starter support bracket. On manual transmission equipped models, remove shift cable bracket and disconnect cable. On all models, remove fuel supply line from support bracket. Remove starter bolts. Remove starter. To install, reverse removal procedure. Tighten bolts to specification.

yes just undo all the rocker cover bolts remove the rocker and make sure that you remove all the old gasket material on the rocker cover and the cylinder head then get some gasket tack(a spray adheasive) put gasket in place and make sure you only tighten them hand tight with a nut driver.start with the inside nuts and work your way to the outside