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 drive belt. Refer to Drive Belt Replacement .
6. Remove the air conditioning compressor discharge hose, if equipped. Refer to Discharge Hose Replacement .
7. Remove the air conditioning compressor suction hose, if equipped. Refer to Suction Hose Replacement .



8. Remove the mounting bolts (2) for the air conditioning compressor (1), if equipped.
9. Move the compressor aside and support.
10. Remove the drive belt idler pulley if not equipped with A/C. Refer to Drive Belt Idler Pulley Replacement - without Air Conditioning .
11. Remove the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement .



12. Remove the 3 bolts holding the power steering pump to the power steering pump mounting bracket.

The power steering pump can remain on the engine.




13. Remove the 3 bolts and nut holding the power steering pump mounting bracket to the engine.
14. Slide the power steering pump mounting bracket off the stud and power steering pump.
15. Remove the power steering pump mounting bracket stud from the cylinder head.
16. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
17. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side .



18. Remove the ground wires at the rear of the cylinder head.
19. Remove the transmission control cable bracket.
20. Remove the valve pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .



21. Remove the engine coolant temperature sensor if applicable.



22. Remove the engine coolant temperature gage sensor if applicable.



23. Remove the spark plugs.



24. Remove the bolts and the spark plug wire support.



25. Remove and discard the cylinder head bolts.



26. Remove the cylinder head.



27. Remove and discard the cylinder head gasket.



28. Remove the dowel pins cylinder head locator if required.
29. 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.

30. Clean the cylinder head bolts and the engine block bolt holes.
31. 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 the spark plug wire support bolts to 12 N·m (106 lb in).




11. Measure the NEW spark plugs for the proper gap.

Adjust the spark plug gap if necessary.

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

12. 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).




13. If reusing the engine coolant temperature gage sensor, if applicable, apply sealant to the threads of the engine coolant temperature gage sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
14. Install the engine coolant temperature gage sensor, if applicable.

Tighten
Tighten the engine coolant temperature gage sensor to 20 N·m (15 lb ft).




15. If reusing the engine coolant temperature sensor, if applicable, apply sealant to the threads of the engine coolant temperature gage sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
16. Install the engine coolant temperature sensor, if applicable.

Tighten
Tighten the engine coolant temperature sensor to 20 N·m (15 lb ft).

17. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .



18. 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).

19. Install the transmission control cable bracket and bolts at the rear of the cylinder head.

Tighten
Tighten the transmission control cable bracket bolts to 40 N·m (30 lb ft).

20. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side .
21. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .



22. Install the stud for the power steering pump mounting bracket to the cylinder head.

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




23. Slide the power steering pump mounting bracket on the stud and the power steering pump.
24. Install the 3 bolts and the nut.

Tighten
Tighten the power steering pump mounting bolts and the nut to 41 N·m (30 lb ft).




25. Install the 3 bolts for the power steering pump.

Tighten
Tighten the power steering pump mounting bracket to the power steering pump bolts to 50 N·m (37 lb ft).

26. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement .
27. Install the air conditioning compressor, if equipped. Refer to Air Conditioning Compressor Replacement .
28. Install the air conditioning compressor discharge hose, if equipped. Refer to Discharge Hose Replacement .
29. Install the air conditioning compressor suction hose, if equipped. Refer to Suction Hose Replacement .
30. Install the drive belt idler pulley if not equipped with A/C. Refer to Drive Belt Idler Pulley Replacement - without Air Conditioning .
31. Install the fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement and to Engine Coolant Fan Lower Shroud Replacement .
32. Fill the engine coolant system. Refer to Cooling System Draining and Filling .
33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
34. Install the engine cover. Refer to Engine Cover Replacement .