Cylinder Head Assembly: Service and Repair

REMOVAL PROCEDURE

^ Tools Required
- J28467-360 Engine Support Fixture

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Remove the accessory 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.
10. Drain and recover the cooling system.
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.
14. Remove the pushrods.
15. Remove the valve lifters.
16. Remove the generator rear brace.
17. Remove the generator.
18. Remove the power steering pump. Position the pump aside with the lines attached.





19. Remove the radiator inlet pipe.
20. Remove the ignition coil assembly.





21. Remove the accessory bracket.
22. Disconnect the secondary ignition wires from the spark plugs.
23. Install the J28467-360. Use a bolt installed in the engine block to attach the engine support fixture.
24. Remove the cylinder head bolts.





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

INSTALLATION PROCEDURE

^ Tools Required
- J36660 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.





4. Install the cylinder head bolts by hand.

IMPORTANT: Use J36660 in order to tighten all the cylinder head bolts an additional 90 degrees in sequence.

NOTICE: Refer to Fastener Notice in Service Precautions.





5. Use the following sequence in order to tighten the cylinder head bolts:
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 (stud bolt) to 58 Nm (43 ft. lbs.).

6. Remove the J28467-360
7. Install the valve lifters. Refer to Valve Lifter Replacement
8. Install the rocker arms.
9. Install the pushrods.
10. Install the valve rocker arm cover.
11. Connect the secondary ignition wires to the spark plugs.





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





14. Install the radiator inlet pipe.
15. Install the power steering pump.





16. Connect the Engine Coolant Temperature Sensor (ECT) electrical connection.
17. Refill the cooling system.
18. Install the exhaust manifold.
19. Install the generator rear brace.
20. Install the generator.
21. Install the intake manifold.
22. Install the engine mount.
23. Install the air cleaner outlet duct.
24. Install the accessory drive belt.
25. Connect the negative battery cable.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).