Cylinder Head Replacement

REMOVAL PROCEDURE

^ Tools Required
- J 28467-360 Engine Support Fixture

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
3. Remove the drive belt.
4. Remove the air cleaner outlet duct.
5. Remove the engine mount.
6. Remove the intake manifold.
7. Remove the exhaust manifold.
8. Disconnect the Engine Coolant Temperature Sensor (ECT) electrical connection.





9. Raise the vehicle. Refer to Vehicle Lift Points.
10. Drain and recover the cooling system. Refer to Cooling System Service and Repair.
11. Lower the vehicle.
12. Remove the valve rocker arm cover.

Important: When removing valve train components keep them in order. Do this to ensure that the components are installed in the same locations and with the same mating surfaces as when removed.

13. Remove the rocker arms and pushrods.
14. Remove the valve lifters.
15. Remove the generator rear brace.
16. Remove the generator.
17. Remove the power steering pump. Position the pump aside with the lines attached.
18. Remove the radiator inlet pipe.
19. Remove the ignition coil assembly.





20. Remove the accessory bracket.
21. Disconnect the secondary ignition wires from the spark plugs.
22. Install the J 28467-360. Use a bolt installed in the engine block to attach the engine support fixture.





23. Remove the cylinder head bolts.
24. Remove the cylinder head.
25. Clean the following components:
^ Head gasket surface.
^ Valve rocker arm cover gasket surface.
^ Threads.


INSTALLATION PROCEDURE

^ Tools Required
- J 36660 Torque Angle Meter

Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket.





1. Install the cylinder head gasket to the block.
2. Use a socket in order to push the cylinder head gasket over the rear dowel pin.





3. Carefully guide the cylinder head into place over the dowel pins. This operation may require an assistant.





Notice: Refer to Fastener Notice in Service Precautions.

Important: Use J 36660 in order to tighten all the cylinder head bolts an additional 90° in sequence.

4. Use the following sequence in order to tighten the cylinder head bolts:
4.1. Tighten bolt 1 to 63 Nm (46 ft. lbs.).
4.2. Tighten bolt 2 to 58 Nm (43 ft. lbs.).
4.3. Tighten bolt 3 to 58 Nm (43 ft. lbs.).
4.4. Tighten bolt 4 to 63 Nm (46 ft. lbs.).
4.5. Tighten bolt 5 to 63 Nm (46 ft. lbs.).
4.6. Tighten bolt 6 to 58 Nm (43 ft. lbs.).
4.7. Tighten bolt 7 to 58 Nm (43 ft. lbs.).
4.8. Tighten bolt 8 to 63 Nm (46 ft. lbs.).
4.9. Tighten bolt 9 to 63 Nm (46 ft. lbs.).
4.10. Tighten bolt 10 (stud bolt) to 58 Nm (43 ft. lbs.).
5. Remove the J 28467-360
6. Install the valve lifters.
7. Install the rocker arms.
8. Install the pushrods.
9. Install the valve rocker arm cover.
10. Connect the secondary ignition wires to the spark plugs.





11. Install the accessory bracket.
12. Install the ignition coil assembly.





13. Install the coolant intake pipe.
14. Install the power steering pump.





15. Connect the Engine Coolant Temperature Sensor (ECT) electrical connection.
16. Refill the cooling system. Refer to Cooling System Service and Repair.
17. Install the exhaust manifold.
18. Install the generator rear brace.
19. Install the generator.
20. Install the intake manifold.
21. Install the engine mount.
22. Install the air cleaner outlet duct.
23. Install the accessory drive belt.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

24. Connect the negative battery cable.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).