GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2007 🢒 G3 🢒 Engine 🢒 Engine Mechanical - 1.6L (L91) 🢒 Cylinder Head Disassemble

Tools Required

    • J 8062 (KM 348) Valve Spring Compressor
    • KM-653-A Adaptor

Disassembly Procedure

    Object Number: 1291215 Size: SH
  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Camshaft Replacement .
  2. Remove the coolant temperature sensor (CTS).
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
  5. Remove the exhaust manifold retaining nuts in the sequence shown.
  6. Remove the exhaust manifold.
  7. Remove the exhaust manifold gasket.
  8. Remove the exhaust manifold studs.

    9. Object Number: 1289655 Size: SH
  9. Remove the thermostat housing mounting bolts.
  10. Remove the thermostat housing assembly.
  11. Remove the fuel rail retaining bolts and the fuel rail assembly.

    12. Object Number: 1291157 Size: SH
  12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown.
  13. Remove the intake manifold.
  14. Remove the intake manifold studs.

    15. Object Number: 1291244 Size: SH
  15. Remove the direct ignition system (DIS) coil mounting bolts.
  16. Remove the DIS coil with the ignition wires attached.
  17. Remove the DIS coil mounting bracket bolts.
  18. Remove the electrical exhaust gas recirculation (EEGR) valve adapter bolts.
  19. Remove the EGR valve adapter bolts.
  20. Remove the EGR valve adapter.
  21. Remove the EGR valve adapter gasket.
  22. Remove the spark plugs.

    23. Object Number: 1291253 Size: SH
  23. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

    24. Object Number: 1289656 Size: SH
  24. Remove the intake camshaft caps. Maintain the correct positions for installation.
  25. Remove the intake camshaft.
  26. Remove the intake valve tappet adjusters.
  27. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
  28. Remove the exhaust camshaft.
  29. Remove the exhaust valve tappet adjusters.
  30. Remove the camshaft seals.

    31. Object Number: 1289657 Size: SH

    Caution: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.

  31. Compress the valve springs with J 8062 and KM-653-A .
  32. Remove the valve keys.
  33. Remove the J 8062 and KM-653-A .
  34. Remove the valve spring caps.
  35. Remove the valve springs. Maintain the original position of the valve springs for installation.

    36. Object Number: 1289658 Size: SH
  36. Remove the valves. Maintain the original position of the valves for installation.
  37. Remove the valve stem seals.