Special Tools

J 45059 Angle Meter

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Drain the engine coolant. Refer to Cooling System Draining and Filling .
4. Remove the fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement and to Engine Coolant Fan Lower Shroud Replacement .
5. Remove the generator mounting bracket. Refer to Generator Bracket Replacement .
6. Remove the generator mounting bracket stud from the cylinder head.
7. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
8. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .



9. Remove the ground wires at the rear of the cylinder head.
10. Remove the valve pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .



11. Remove the spark plugs.



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



13. Remove and discard 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, and Valve and Seat Grinding or Cylinder Head Assemble .

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 NEW cylinder head bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
7. Install the cylinder head bolts finger tight.

Notice: Refer to Fastener Notice in the Preface section.




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

Tighten
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

•	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
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.

Specification
Spark plug gap to 1.52 mm (0.060 in).

13. Install the spark plugs.

Tighten

•	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. Refer to Valve Rocker Arm and Push Rod Replacement .



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

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

16. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
17. Install the intake manifold. Refer to Lower Intake Manifold Replacement .



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

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

19. Install the generator mounting bracket. Refer to Generator Bracket Replacement .
20. Install the fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement and to Engine Coolant Fan Lower Shroud Replacement .
21. Fill the engine coolant system. Refer to Cooling System Draining and Filling .
22. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
23. Install the engine cover. Refer to Engine Cover Replacement .