Cylinder Head Assembly: Specifications
Service DataINSPECT CYLINDER HEAD FOR FLATNESS
a. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage.
Maximum warpage:
Cylinder block surface 0.05 mm (0.0020 inch)
Intake manifold surface 0.10 mm (0.0039 inch)
Exhaust manifold surface 0.10 mm (0.0039 inch)
If warpage is greater than maximum, replace the cylinder head.
INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.
Torque Specification
CYLINDER HEAD LH
NOTICE: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a light coat of engine oil on the threads of the cylinder head bolts
b. Install the plate washer to the cylinder head bolt.
c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step c.
f. Check that each painted mark is now at a 90° angle to the front.
g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Install the bolt holding the water inlet to the cylinder head. (TMMWV MADE)
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
i. Install the wire harness clamp bracket with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
j. Connect the ground cable with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
CYLINDER HEAD RH
NOTICE: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.
c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step c.
f. Check that each painted mark is now at a 90° angle to the front.
g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d. Connect the heater inlet water hose.
EXHAUST MANIFOLD CONVERTER SUB-ASSY
a. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.