Head gasket replacement--'00 deville--how does front valvecover come off at water pump pulley? 10-10mm head bolts off and 1 under cam chain--what others are there?

need a harmonic balancer pulley you can rent them at your local auto part store

Removal & Installation

3.5L Engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Record the radio anti theft code data.
3. Remove or disconnect the following:
   
   Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
   
4. Support the engine with a floor jack and remove the engine mount.
5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.
   
   

   Fig. Timing belt routing and timing marks-3.5L Engine
   

6. Remove or disconnect the following:
   
   Auto tensioner Timing belt
   
   

   Fig. Timing belt and related components-3.5L Engine
   
   

To install:

1. Ensure that the engine is set to Top Dead Center (TDC).
2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
3. Install the timing belt in the following order:
   1. Crankshaft sprocket
   2. Idler pulley
   3. Left bank exhaust camshaft sprocket
   4. Left bank intake camshaft sprocket
   5. Water pump pulley
   6. Right bank intake camshaft sprocket
   7. Right bank exhaust camshaft sprocket
   8. Tensioner pulley
   
   
4. Install the auto tensioner. Do not remove the retaining pin at this time.
5. Check that the crankshaft and camshaft timing marks are aligned correctly.
6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
8. Loosen the tensioner pulley center bolt.
9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).
   
   

   Fig. Adjusting the tensioner pulley-3.5L Engine
   

10. Remove the auto tensioner retaining pin.
11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.
    
    

    Fig. Measuring the auto tensioner rod-3.5L Engine
    

13. When the auto tensioner measurement is correct, install or connect the following:
    
    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
    
14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    • REMOVAL & INSTALLATION

    Print
    

    
    Removal & Installation
    
    3.8L Engine
    

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
        
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
        
        

        Fig. Timing chain and related components-3.8L Engine
        

    
    To install:
    
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
       
       

       Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
       

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
        
        

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
        

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Sealant application (1 inch bead width)-3.8L Engine
        

    23. Apply sealant on the chain cover.
        NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Timing cover sealant application-3.8L Engine
        

    24. Install a new gasket to the timing case cover.
        NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
        
        
        

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine
        

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.
        
        

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine
        

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

Check your owner's manual for the recommended mileage for replacing your timing chain. Replacement for a Nissan Maxima is 60,000 miles.2 Locate the timing chain. Replace it if the automatic chain adjuster (also known as the tensioner) is damaged or worn.3 Release the pressure in the fuel system, drain the cooling system and disengage the negative battery cable. 4 Undo the upper radiator hose, engine drive belts, power steering pulley and pump with bracket, air duct, passenger front wheel and engine side and undercovers, front exhaust pipe, cylinder head front mounting bracket and head cover, rocker cover, distributor and distributor cap and spark plugs.5 Take off the intake manifold support and move the No. 1 piston at "Top Dead Center" (TDC) of the compression stroke.6 Disconnect the cylinder head front cover, water pump pulley, thermostat housing, upper and lower tensioner and slack side timing chain guide, idler sprocket bolt, camshaft sprocket bolts, sprockets, mounting caps and camshafts. 7 Disengage the cylinder head with the manifolds, idler sprocket shaft, upper timing chain, center crossmember, oil pan and strainer assembly, crankshaft pulley, engine front mount and bracket and the front timing cover. Remove the oil seal and unfasten the timing chain cover, idler and crankshaft sprockets and the oil pump drive spacer. 8 Unfasten the timing chain guide. install Your Timing Chain 1 Grease the oil seal lip with engine oil and place it in the front cover. Verify that the No. 1 piston is at "Top Dead Center" (TDC) of the compression stroke. 2 Reconnect the crankshaft sprocket (marks should point toward the engine's front), oil pump drive spacer and timing chain guide and the lower timing chain. Line up all mating marks.3 Hook up the crankshaft sprocket and pulley, lower timing chain, front cover assembly, engine mount and front mounting bracket, oil strainer and pan assembly and center crossmember.4 Reattach the upper timing chain, idler sprocket (to the back side), cylinder head assembly, idler sprocket bolt and exhaust and intake camshafts. Place the intake camshaft knock pin at 9 o'clock and the exhaust pin at noon. Connect the camshaft bearing caps and distributor brackets and secure all mounting bolts.5 Eliminate any old material from the pan and cylinder block mounting surfaces. Rub on a 3.5 to 4.5mm bead of liquid gasket over the oil pan and cylinder block.6 Attach the upper timing chain to the idler sprockets and secure the cylinder head bolts.7 Refill the cooling system. Hook up the negative battery cable and any other disconnected items. Start the engine and look for leaks.

Installation
Install crankshaft sprocket on crankshaft.
Make sure mating marks on crankshaft sprocket face front of engine.

Position crankshaft so that No. 1 piston is at TDC and crankshaft key is at 12 o'clock.

Install slack side timing chain guide and timing chain tension guide.

Install timing chain on crankshaft sprocket.
Set timing chain by aligning its mating mark with that on the crankshaft sprocket.
Make sure sprocket's mating mark faces engine front.

Install camshaft sprockets.
Set timing chain by aligning mating marks with those of camshaft sprockets.

Install camshaft sprocket bolts to correct torque.
Apply new engine oil to bolt threads and seat surface.

Install chain tensioner.
Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner.
After installing chain tensioner, remove the pin.
Install timing chain guide.

Install O-rings to cylinder block.

Before installing front cover, remove all traces of RTV silicone sealant from mating surface using a scraper.
Also remove traces of RTV silicone sealant from mating surface of cylinder block.

Apply a continuous bead of Genuine RTV Silicone Sealant or equivalent to mating surface of front cover. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
Check alignment of mating marks on chain and crankshaft sprocket.
Align oil drive spacer with oil pump.
Place timing chain to the side of chain guide. This prevents the chain from making contact with water seal area of front cover.

Install front cover.

Make sure two O-rings are present.

Be careful not to damage oil seal when installing front cover.
Install cylinder head bolts at engine front side as shown in Fig. 55.
Tightening procedure:
Tighten bolts (1 - 4): 6.3-8.3 N.m (0.64-0.85 kg.m, 55.8-73.5 in.lb).

Install oil pump drive spacer.
Install water pump and water pump pulley. Refer to REMOVAL AND INSTALLATION .
Install idler pulley and bracket.

Install RH engine mounting bracket

Install RH engine mounting.
Install oil pan. Refer to INSTALLATION.
Install crankshaft pulley.
Remove ring gear stopper.
Install starter motor.
Install cylinder head front cover.
Apply RTV silicone sealant to cylinder head front cover.
Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .

Install Camshaft Position Sensor (PHASE).

Before installing rocker cover, apply a bead of Genuine RTV Silicone Sealant or equivalent, to mating surface of cylinder head as shown in .

Install rocker cover gasket into rocker cover.
Install rocker cover and tighten in numerical order as shown in
Install spark plugs.
Install ignition coils.
Install front exhaust tube.
Install front/right-side splash undercover.
Install front RH wheel.
Install drive belts.
Adjusting drive belt deflection..

Timing Chain & Gears Removal & Installation To Remove:
NOTE: Keep the cam chain away from magnetic fields.
Crankshaft set at TDC marks

1. Turn the crankshaft pulley so its Top Dead Center (TDC) mark (1) lines up with the pointer (2).
2. Raise and support the vehicle.
3. Remove the front tires/wheels. Front undercar splash shield
   
   
4. Remove the front undercar splash shield.
5. Remove the drive belt.
6. Remove the cylinder head cover (See section on Valve Cover).
7. Remove the crankshaft pulley (See section on Crankshaft Damper). CKP sensor and VTC solenoid electrical connectors
   
   
8. Disconnect the Crankshaft Position (CKP) sensor connector (1) and Variable Valve Timing Control (VTC) oil control solenoid valve connector (2).
9. Remove the VTC oil control solenoid valve (See section on VTC Solenoid Valve).
10. Support the engine with a jack and wood block under the oil pan. Ground cable and upper bracket removal
    
    
11. Remove the ground cable (1), and remove the upper bracket (2). Side engine mount bracket removal
    
    
12. Remove the side engine mount bracket. Timing chain cover removal
    
    
13. Remove the timing chain cover bolts both from the front to the block and from the bottom to the oil pan.
14. Remove the timing chain cover.
15. Loosely install the crankshaft pulley. Compress the timing chain auto-tensioner
    
    
16. Turn the crankshaft counterclockwise to compress the auto-tensioner. Lock the timing chain auto-tensioner
    
    
17. Align the holes on the lock (1) and the auto tensioner (2), and then insert a 0.06 inch (1.5 mm) diameter pin (3) into the holes.
18. Turn the crankshaft clockwise to secure the pin. Removal of the timing chain auto-tensioner
    
    
19. Remove the auto-tensioner. Removal of the timing chain guide B
    
    
20. Remove the cam chain guide B. Removal of the timing chain guide A
    
    
21. Remove the cam chain guide A (1) and tensioner arm (2).
22. Remove the cam chain.

Removal & Installation 2.2L Engine To Remove:

1. Disconnect the battery ground cable.
2. If equipped with an automatic transmission, remove the exhaust manifold..
3. Drain the cooling system.
4. Raise and safely support the vehicle.
5. Remove or disconnect the following:
   • Right front wheel and tire assembly.
   • Right front fender liner.
     
     
   • Access plate on the water pump sprocket from the timing cover.
6. Install J 43651 water pump sprocket holder or equivalent to the water pump sprocket.
7. Use the access plate bolts to attach J43651 to the engine front cover.
8. Remove or disconnect the following:
   • Bolts that secure the sprocket to the water pump.
   • Bolt that secures the engine block to the water pump.
   • Bolt that secures the engine front cover to the water pump.
   • Feed pipe that joins the thermostat housing to the water pump.
     
     
   • 2 Bolts that secure the water pump to the engine block.
   • Water pump.

To Install:

1. Use a threaded stud in the hub to align the water pump sprocket.
2. Install or connect the following:
   • Water pump.
   • 2 bolts that secure the water pump to the engine block.
   • Feed pipe that joins the thermostat housing to the water pump.
   • Front cover bolt and the bolt that secures the engine block to the water pump. Tighten the bolts to 15 ft lbs (20 Nm).
   • 2 of the bolts that secure the water pump sprocket to the water pump.
3. Remove the threaded stud.
4. Install the last bolt.
   • Tighten the bolts to 89 in lbs (10 Nm).
5. Remove J 43651.
6. Install the access plate on the water pump sprocket to the timing cover.
7. Install the access plate bolts.
   • Tighten the bolts to 18 in lbs (10 Nm).
8. Install the front fender liner.
9. Install the right front tire and wheel.
10. If equipped with an automatic transmission, install the exhaust manifold.
11. Fill the cooling system.
12. Connect the battery ground cable.

2.4L Engine To Remove:
Water pump 2.4L

1. Disconnect the negative battery cable
2. Drain the engine coolant.
3. Remove the exhaust manifold.
4. Remove the coolant intake pipe as follows:
   1. Remove the coolant inlet pipe bolts.
   2. Remove the wheel and tire assembly.
   3. Remove the engine splash shield.
   4. Remove the bolts from the transaxle-to-engine block brace and remove the brace.
   5. Remove the radiator hose from the coolant inlet pipe.
   6. Remove the coolant inlet pipe to oil pan bolt.
   7. Remove the coolant inlet pipe, thermostat and seal.
5. Lower the vehicle.
6. Disconnect the heater hose quick connect from the heater outlet pipe.
7. Remove the front timing chain cover and the chain tensioner.
8. Unfasten the water pump-to-cylinder block bolts.
9. Remove the water pump-to-timing chain housing nuts.
10. Remove the water pump and cover mounting bolts and nuts.
11. Remove the water pump and cover as an assembly. Separate the two pieces after removal.
12. Clean the mating surfaces.

To Install:

1. Install the water pump cover to the water pump assembly.
2. Install and hand tighten the pump cover mounting bolts.
3. Install water pump cover assembly.
4. Install and hand tighten the cover-to-block mounting bolts.
5. Install and hand tighten the water pump-to-timing chain housing nuts.
   • Tighten the water pump-to-timing chain housing mounting nuts to 19 ft lb (26 Nm).
   • Tighten the water pump cover-to-water pump mounting bolts to 124 in lb (14 Nm).
   • Tighten the water pump cover-to-engine block bolts starting with the bottom bolt first to 19 ft lb (26 Nm).
6. Install the heater hose to the water pump pipe.
7. Using new gaskets, install the exhaust manifold.
8. Install the oil level indicator and tube.
9. Connect the brake vacuum tube to the cam housing.
10. Raise and safely support the vehicle.
11. Install the catalytic converter.
12. Install the coolant inlet pipe.
    • Tighten the inlet pipe-to-oil pan bolt to 19 ft lb (26 Nm). Tighten the coolant inlet pipe bolt to 124 in lb (14 Nm).
13. Install the timing chain and tensioner.
14. Lower the vehicle.
15. Connect the oxygen sensor.
16. Fill cooling system and check the system for leaks.

3.4L Engine To Remove:

1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Loosen the water pump pulley bolts.
4. Remove or disconnect the following:
   • Drive belt.
   • Water pump pulley bolts and pulley.
   • Water pump bolts, pump and gasket.
   • Clean the water pump mating surfaces.

To Install:

1. Install or connect the following:
   • Water pump gasket and pump.
   • Water pump bolts.
     1. Tighten the water pump bolts to 89 in lbs (10 Nm).
   • Water pump pulley and bolt until snug.
   • Drive belt.
2. Tighten the water pump pulley bolts to 18 ft. lbs (25 Nm).
3. Fill the cooling system.
4. Check for leaks.
5. Connect the battery ground cable.

REMOVAL & INSTALLATION NOTE: The manufacturer recommends that the entire powertrain be removed from the vehicle before removing the cylinder heads.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Properly relieve the fuel system pressure.
4. Remove or disconnect the following:
   • Negative battery cable
   • Powertrain assembly
   • Intake manifold
   • Cam covers
   • Harmonic balancer
   • Timing chain front cover
   • Oil pump
   WARNING
   Align all timing marks before performing the next step.
   • Chain tensioner from the timing chain
   • Cam sprockets
   NOTE: The timing chain remains in the chain case.
   • Timing chain guides, access for the retaining screws is through the plugs at the front of the cylinder head
   • Water crossover
   • Exhaust manifold
   • Cylinder head bolts by reversing the torque sequence
   • Cylinder head and discard the gasket
   WARNING
   With the camshafts remaining in the cylinder head some valves will be open at all times. Do not rest the cylinder head on a flat service with the cylinder face down, or valve damage will result. NOTE: Clean all gasket mating surfaces. Clean the head bolt holes in the crankcase. WARNING
   Be careful when cleaning aluminum gasket surfaces to prevent damage to the sealing surfaces.
   
5. Check the cylinder head for warpage; it must be less than 0.002 in. (0.05mm). If the cylinder head was resurfaced, the dimension between the combustion chamber gauge pad and the deck surface must be at least 10.5mm. To install: NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
   
6. Install or connect the following:
   • New cylinder head gasket
   • Cylinder head, lubricate the bolts with engine oil
7. Torque the M11 bolts, in sequence, as follows:
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: Turn an additional 60 degrees.
   3. Step 3: Turn an additional 60 degrees (total 180 degrees).
8. Torque the M6 bolts to 106 inch lbs. (12 Nm).
9. Set the camshaft timing
10. Camshaft guide bolt access hole plugs in the cylinder heads. The plugs should be seated and snug
11. Install or connect the following:
    • Intake cam covers
    • Oil pump
    • Timing chain front cover
    • Harmonic balancer
    • Cam sprockets
    • Chain tensioner to the timing chain
    • Timing chain guides
    • Intake manifold
    • Water crossover
    • Exhaust manifold. Torque the nuts to 22 ft. lbs. (30 Nm) or the bolts to 18 ft. lbs. (25 Nm).
    • Powertrain assembly
    • Negative battery cable Fig. 1: Minimum head resurface dimension
      
    
    
12. Fill the cooling system.
13. Evacuate and charge the air conditioning system.
14. Run the engine and check for leaks.

Depends on your engine, the 1.6 Korean engine used the water pump as a tensioner and idler. The 2.0 had separate tensioners. And the V6 had a chain. The tensioners are not hard to find, you need to remove the front covers to get to them. If you are changing the belt and tensioner, I would do the water pump too. You have it open, might as well. Hope this helps.

Per Chilton's Repair Manual: You're dealing with aluminum so pay careful attention not to exceed recommended torque.

4.5L And 4.9L Engines

1. Disconnect the negative battery cable.
   
2. Drain and recycle the engine coolant.
   
3. Remove the air filter assembly. Disconnect and remove the coolant recovery tank.
   
4. Disconnect and remove the cross brace.
   
5. Remove the water pump pulley bolts.
   
6. Remove the serpentine drive belt and the water pump pulley.
   
7. Remove the water pump-to-engine bolts and the pump.
   

Water pump assembly—4.5L and 4.9L engines
To install:

1. Clean the gasket mounting surfaces.
   
2. Place a new gasket over the water pump studs.
   
3. Install the water pump. Tighten the water pump bolts as follows:
   
   1. Water pump-to-engine Torx® bolts to 30 ft. lbs. (40 Nm)
      
   2. Water pump-to-engine stud nuts to 5 ft. lbs. (7 Nm)
      
   3. Hex head bolts to 30 ft. lbs. (40 Nm)
      
   4. Remaining hex head bolts to 5 ft. lbs. (7 Nm).
      
4. Install the water pump pulley. Install the water pump pulley bolts finger-tight.
   
5. Install the serpentine drive belt.
   
6. Tighten the water pump pulley bolts to 22 ft. lbs. (30 Nm).
   
7. Install the cross brace.
   
8. Install and connect the coolant recovery tank. Install the air filter assembly.
   
9. Connect the negative battery cable.
   
10. Fill cooling system and check for leaks. Start the engine and allow it to come to normal operating temperature. Recheck for leaks. Top-up the coolant.
    

Yes, the chain has to come off. The cam gear that is driven by the chain is mounted on the cam, inside the head, and the crank pulley down at the bottom is what drives it via the chain. The chain has to be removed in order to remove the head.

Usually the pulleys are mounted onto their shafts with a bolt through the center of each pulley. That will have to be loosened and removed (which is much easier if it's loosened before you remove the chain, so that the chain holds the pulley still and keeps it from moving). My question is, why do you need to remove the pulley? Once the chain is off, and everything else is disconnected, the head will lift off with the pulley intact, and the crank pulley doesn't need to come off as it has nothing to do with a head gasket service. Is there another issue that requires the pulley to come off, or are you replacing the head with one whose cam pulley is missing?