Special Tools

J 36660-A Torque Angle Meter

1. Remove the engine cover. Refer to Engine Cover Replacement.



2. Remove the cooling layer. Refer to Cooling Layer Removal.
3. Remove the generator bracket. Refer to Generator Bracket Replacement.
4. Remove the water crossover. Refer to Engine Coolant Crossover Pipe Replacement.
5. Remove the intake manifold. Refer to Intake Manifold Replacement.
6. Remove the valve rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement.
7. Remove the engine coolant temperature (ECT) sensor clip from the bracket.
8. Remove the ECT sensor from the engine block.



9. Remove the ECT sensor bracket bolt and bracket.
10. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.



11. Remove and discard the cylinder head bolts (1, 2, 3).




Note: Place the cylinder head on 2 wood blocks to prevent damage to the sealing surface.

12. Remove the cylinder head.



13. Remove and discard the cylinder head gasket.
14. Clean and inspect the cylinder head.

Note: Make sure the threaded holes in the engine block are clean and not damaged. Do not use sealer on any engines that use a composition type gasket. Align the cylinder head gasket locating marks to face up. Ensure that the head gasket tabs are located over the numbers 1 and 2 cylinders for correct installation.

1. Place a new cylinder head gasket into position.



2. Install the cylinder head.




Caution: Do not reuse the cylinder head bolts. NEW cylinder head bolts must be used. The cylinder head bolts are torque-to-yield bolts and cannot be reused once the initial torque is applied. During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load. Proper clamp load will not be achieved if a used cylinder head bolt is torqued again. A stretched cylinder head bolt can also break when torqued. Failure to replace the used cylinder head bolts with NEW cylinder head bolts can lead to improper clamp loads and extensive engine damage.

Caution: Do not reuse a cylinder head gasket once the initial clamping loads are applied. The initial tightening sequence procedure of the cylinder head bolts compresses the cylinder head gasket. If any bolt must be loosened once the initial sequence is started the cylinder head gasket must be replaced. Failure to replace the cylinder head gasket can lead to cylinder head bolt breakage or cylinder head gasket failure. A broken cylinder head bolt or failed cylinder head gasket can lead to extensive engine damage.

Caution: The cylinder head bolt tightening sequence must be followed. The final angle tightening sequence of the cylinder head bolts varies depending on the length of the cylinder head bolt. Failure to angle tighten the specific length bolt the proper number of degrees can lead to cylinder head bolt failure or improper clamping load of the cylinder head gasket. Cylinder head bolt or cylinder head gasket failure can lead to extensive engine damage.

Note: The sealer must be applied to a minimum of eight threads starting at the point of the cylinder head bolt.

3. If not pre-applied to the new cylinder head bolts (1, 2, 3), apply sealer to the cylinder head bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

Caution: Refer to Fastener Caution in the Preface section.





Note: The long bolts are used in locations 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, and 17. The medium length bolts are used in locations 15 and 18. The short bolts are used in locations 4, 5, 12, and 13.

4. Install the cylinder head bolts.

Tighten

1. Tighten the cylinder head bolts a first pass in sequence to 30 N·m (22 lb ft).
2. Tighten the cylinder head bolts a second pass in sequence to 30 N·m (22 lb ft) then an additional 120 degrees using J 36660-A .
3. Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17) an additional 60 degrees, bolts (15 and 18) an additional 45 degrees, and bolts (4, 5, 12, and 13) an additional 30 degrees using J 36660-A .
5. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.



6. Install the ECT sensor bracket and bolt.

Tighten
Tighten the engine coolant temperature sensor bracket bolt to 50 N·m (37 lb ft).




7. Apply sealer to the threads of the ECT sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
8. Install the ECT sensor to the engine block.

Tighten
Tighten the ECT sensor to 20 N·m (15 lb ft).

9. Install the ECT sensor clip to the bracket.
10. Install the valve rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement.
11. Install the intake manifold. Refer to Intake Manifold Replacement.
12. Install the water crossover. Refer to Engine Coolant Crossover Pipe Replacement.
13. Install the generator bracket. Refer to Generator Bracket Replacement.
14. Install the cooling layer. Refer to Cooling Layer Installation.
15. Install the engine cover. Refer to Engine Cover Replacement.