Cylinder Head Replacement

Cylinder Head Replacement

^ Tools Required
- J 36660-A Torque Angle Meter

Removal Procedure





1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the engine cooling fan clutch.
4. Remove the engine drive belt.
5. Remove the fan pulley.
6. Remove the generator.
7. Remove the A/C compressor, if equipped.
8. Remove the power steering pump.
9. Remove the thermostat assembly.





10. Remove the bolts holding the accessory mounting bracket to the engine.
11. Remove the accessory mounting bracket.
12. Remove the exhaust manifold.
13. Remove the valve rocker arm cover.
14. Remove the valve rocker arms and push rods.
15. Remove the intake manifold.





16. Remove the engine lift bracket from the rear of the engine.





17. Remove the cylinder head bolts.
18. Remove the cylinder head.
19. Remove and discard the cylinder head gasket.





20. Clean the following areas:
^ Clean any carbon deposits from the combustion chambers.
^ Clean all traces of the old cylinder head gasket from the cylinder head and from the engine block.

Important: Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad will damage the cylinder head and block surfaces. Abrasive pads also produce a fine grit that will contaminate the engine oil.

It is only necessary to remove the gasket material. Do not attempt to remove all marks from the cylinder head gasket surfaces.
^ Clean the cylinder head bolt threads.
^ Clean the threads that are in the engine block.
21. Inspect the engine block to cylinder head mating surface for the following conditions:
^ Nicks
^ Heavy scratches
^ Any other damage
^ For further service to the cylinder head refer to the following:
^ Cylinder Head Disassemble
^ Cylinder Head Cleaning and Inspection
^ Valve Guide Reaming/Valve and Seat Grinding
^ Cylinder Head Assemble

Installation Procedure

Important: Install the NEW cylinder head gasket with the words THIS SIDE UP showing.





1. Install the cylinder head gasket to the block.
2. Use a socket 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.





4. Install the cylinder head bolts by hand.





5. Use the following sequence in order to tighten the cylinder head bolts:

Notice: Refer to Fastener Notice in Service Precautions.

^ Tighten the long cylinder head bolts to 63 Nm (46 ft. lbs.).
^ Tighten the short cylinder head bolts to 58 Nm (43 ft. lbs.).
5.1. Tighten bolt 1 to 63 Nm (46 ft. lbs.).
5.2. Tighten bolt 2 to 58 Nm (43 ft. lbs.).
5.3. Tighten bolt 3 to 58 Nm (43 ft. lbs.).
5.4. Tighten bolt 4 to 63 Nm (46 ft. lbs.).
5.5. Tighten bolt 5 to 63 Nm (46 ft. lbs.).
5.6. Tighten bolt 6 to 58 Nm (43 ft. lbs.).
5.7. Tighten bolt 7 to 58 Nm (43 ft. lbs.).
5.8. Tighten bolt 8 to 63 Nm (46 ft. lbs.).
5.9. Tighten bolt 9 to 63 Nm (46 ft. lbs.).
5.10. Tighten bolt 10 to 58 Nm (43 ft. lbs.).
5.11. Use J 36660-A to tighten all the cylinder head bolts an additional 90 degrees in sequence.





6. Install the engine lift bracket onto the rear of the engine.
^ Tighten the engine lift bracket nut to 50 Nm (37 ft. lbs.).





7. Install the intake manifold.
8. Install the valve rocker arms and push rods.
9. Install the valve rocker arm cover.
10. Install the exhaust manifold.
11. Install the accessory mounting bracket.
12. Install the bolts holding the accessory mounting bracket to the engine.
^ Tighten the accessory mounting bolts to 50 Nm (37 ft. lbs.).
13. Install the thermostat assembly.
14. Install the A/C compressor, if equipped.
15. Install the power steering pump.
16. Install the generator.





17. Install the fan pulley.
^ Tighten the fan pulley bolts to 30 Nm (22 ft. lbs.).
18. Install the engine drive belt.
19. Install the engine cooling fan clutch.
20. Fill the cooling system.
21. Connect the negative battery cable.