How to remove the cylinder - Kwikset 94050-354 Entry Delta Lever

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

REMOVAL
1. Drain engine coolant from radiator and cylinder block by removing the drain plugs.
2. Remove the intake manifold.
3. Remove exhaust manifold.
4. Remove camshafts.
5. Remove valve tappets from cylinder head, then support front of engine with wood block between crankshaft pulley and front subframe.
6. Remove righthand engine lifting eye bolt, then righthand engine lifting eye.
7. Remove power steering pump mounting bracket and cylinder head support bracket.
8. Remove camshaft timing belt tensioner pulley and front cover from front of cylinder head.
9. Remove water thermostat housing from cylinder head as follows:
a. Raise and support vehicle.
b. Disconnect crankcase ventilation tube from positive crankcase ventilation valve.
c. Disconnect upper radiator hose and radiator overflow hose from water hose connection.
d. Remove water outlet connection bolts and water hose connection from water thermostat housing.
e. Remove water thermostat and seal from water thermostat, then seal from water thermostat housing. Inspect seals for damage and replace if necessary.
10. Remove ignition coil bracket from cylinder head as follows:
a. Disconnect fuel charging wiring or engine control sensor wiring from ignition coil, then ignition wires by squeezing locking tabs and twisting while pulling upward.
b. Remove ignition coil bolts or screws, then coil.
c. Remove ignition coil bracket.

Fig. 11 Cylinder head bolt removal sequence


11. Remove spark plugs from cylinder head, then cylinder head bolts in sequence. Discard cylinder head bolts.
12. Remove cylinder head and head gasket from cylinder block.
13. If necessary, remove lefthand engine lifting eye from cylinder head.
14. Inspect cylinder head and cylinder block, then replace components as required.

INSTALLATION
1. Reverse procedure to install, noting following:
a. Clean cylinder head intake manifold, valve cover and cylinder head gasket surfaces. Ensure flatness of cylinder head and cylinder block gasket surfaces meets specifications.

Fig. 12 Cylinder head bolt tightening sequence



b. Torque new cylinder head bolts in sequence, first to 15-22 ft lb, then to 30-37 ft lb. Finally tighten all bolts an additional 90-120° in the same sequence.

Check to see that the cylinders are exactly the same.
Try replacing and removing the original.

First drain oil at slave cylinder, then remove pipe from master cylinder . disconnect clutch pedal push rod from cylinder , remove bolts holding cylinder to fire wall remove cylinder. wash off any fluid with water as it will damage paint .

TO REMOVE THE IGNITION SWITCH FIRST TURN OFF RADIO.AND DISABLE AIRBAGS BY DISCONNECTING NEGATIVE BATTERY CABLE WAITING 20 MINUTES UNTIL AIRBAGS DISCHARGE.TO REMOVE IGNITION SWITCH PLACE THE IGNITION KEY IN THE ACC POSITION. REMOVE THE STEERING WHEEL AND REMOVE THE STEERING COLUMN COVERS.DISCONNECT THE IGNTION SWITCH ELECTRICAL CONNECTORS.REMOVE THE SWITCH RETAINING SCREWS THEN PULL THE SWITCH FROM THE LOCK CYLINDER HOUSING.IF YOU TRYING TO REMOVE THE LOCK CYLINDER WITH LOCK CYLINDER IN ACC POSITION. USE A SMALL SCREW DRIVER OR PUNCH. DEPRESS THE LOCK CYLINDER RETAINING PIN THEN REMOVE LOCK CYLINDER. TO INSTALL NEW LOCK CYLINDER. DEPRESS THE RETAINING PIN AND GUIDE THE LOCK CYLINDER INTO THE HOUSING UNTIL THE RETAINING PIN EXTENDS ITSELF BACK INTO THE LOCATING HOLE IN THE HOUSING.

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
    

1. Spark plugs removal

1.1. Front cylinder bank spark plugs removal:
1.1.1. Disconnect the battery from car terminals.
1.1.2. Remove the engine plastic cover.
1.1.3. Disconnect the ignition coils electrical supply cable and all three coils connectors.
1.1.4. Remove all three ignition coils screws.
1.1.5. Remove all three ignition coils out from cylinder head.
1.1.6. Remove all three spark plugs out from cylinder head (straight forward).

1.2. Back cylinder head bank spark plugs removal:
1.2.1. Remove the inlet manifold out from cylinder head.
1.2.2. Disconnect all three ignition coils connectors.
1.2.3. Remove all three ignition coils screws.
1.2.4. Remove all three ignition coils out from cylinder head.
1.2.5. Remove all three spark plugs out from cylinder head (straight forward).

2. Spark plugs installation

2.1. Refit all in reverse order.
2.2. Spark plugs tightening torque = 2,8 +/- 0,3 daN.m
2.3. Ignition coils tightening torque = 0,8 +/- 0,2 daN.m

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.

Removal & Installation

1. Remove the front wheel.
   
2. Drain the brake fluid.
   
3. Remove the union bolt and gasket from the disc brake cylinder and disconnect the flexible hose.
   
4. Remove the disc brake cylinder sub-assembly.
   
5. Remove the disc brake pad kit.
   
6. Remove the two disc brake pad support plates from the cylinder mounting.
   
7. Remove the two cylinder slide pins from the disc brake cylinder mounting.
   
8. Remove the two bolts and the disc brake cylinder mounting.
   
9. Remove the disc.
   
10. Immediately, matchmark the disc to the axle hub.
    

To install:

1. Installation is the reverse of removal.
   
2. Torque the disc retaining bolts to 76 ft. lbs. (103 Nm).
   

Ignition Switch REMOVAL & INSTALLATION The ignition switch is located at the bottom of the ignition key cylinder body. To remove the ignition switch, first remove the ignition lock cylinder.

1993–99 Golf and Jetta

1. Disconnect the negative battery cable.
2. Center the steering wheel.
3. Remove the air bag.
4. Remove the steering column switches.
5. If the vehicle is equipped with an automatic transmission, detach the shift lock cable from the lock cylinder housing.
6. Remove the adapter sleeve from the steering column.
7. Remove the spring and horn contact ring from the steering column assembly.
8. Detach the sheer bolt.
9. Insert the ignition key and unlock the cylinder, then detach the wiring connectors.
10. Once all wiring has been detached, slide the housing off the steering column.
11. Mark and drill the lock cylinder as shown and described in the above procedure.
12. Compress the stop spring and pull the lock cylinder out of the steering column housing.
13. Put the new lock cylinder into the steering lock housing.
14. Insert the key into the lock cylinder.
15. While you gently turn the key, insert the lock cylinder fully into the housing.
16. The rest of the installation procedure is the reverse of removal. NOTE: Always use a new shear pin when installing the lock cylinder.
    

to removal clutch cylinder first remove the pin which holding cylinder and pedal it under just follow the pedal,then open the bonnet have look where fitted clutch cylinder loose the pipe just 10mm spanner then remove to nut which is 12mm spanner then it is out.
if you want to put new kit use to hold cylinder with vise then remove dust cover then remove carlip then just remove old.
to put the new kit clean first check also inside the cylinder if there any sine scratches if not use some brake oil put some in the cylinder before you put the new kit then fixed and plead to take air in the system.