Cylinder Head Replacement - Right

Cylinder Head Replacement - Right Side

Tools Required

J 45059 Angle Meter

Removal Procedure




1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Drain the engine coolant.
4. Remove the fan shroud.
5. Remove the generator mounting bracket.
6. Remove the generator mounting bracket stud from the cylinder head.
7. Remove the lower intake manifold.
8. Remove the exhaust manifold.




9. Remove the ground wires at the rear of the cylinder head.
10. Remove the valve pushrods.




11. Remove the spark plugs.




12. Remove the rear bolt and the spark plug wire support.




13. Remove the cylinder head bolts.




14. Remove the cylinder head.




15. Remove and discard the cylinder head gasket.




16. Remove the dowel pins (cylinder head locator), if required.
17. Clean the engine block and the cylinder head sealing surfaces.

Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

18. Clean the cylinder head bolts and the engine block bolt holes.
19. 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 or Cylinder Head Assemble.

Installation Procedure




1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.





Important: Do not use any type sealer on the cylinder head gasket, unless specified.

4. Install the NEW cylinder head gasket in position over the dowel pins cylinder head locator.




5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.




6. Apply sealant to the threads of the cylinder head bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
7. Install the cylinder head bolts finger tight.





Notice: Refer to Fastener Notice.

8. Tighten the cylinder head bolts in sequence on the first pass.

Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).

9. Using the J 45059 tighten the cylinder head bolts in sequence on the final pass.
^ Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees.
^ Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees.
^ Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.




10. Install the spark plug wire support and bolts.

Tighten only the rear spark plug wire support bolt to 12 N.m (106 lb in).

11. Remove the front spark plug wire support bolt.
The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.




12. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.

Spark plug gap to 1.52 mm (0.060 in).

13. Install the spark plugs.
^ Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft).
^ Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).

14. Install the valve pushrods.




15. Install the ground wires and nut at the rear of the cylinder head.

Tighten the ground wire nut to 10 N.m (88 lb in).

16. Install the exhaust manifold.
17. Install the intake manifold.




18. Install the stud for the generator mounting bracket to the cylinder head.

Tighten the generator mounting bracket stud to 20 N.m (15 lb ft).

19. Install the generator mounting bracket.
20. Install the fan shroud.
21. Fill the engine coolant system.
22. Connect the battery negative cable.
23. Install the engine cover.