Removal and Installation

This procedure can be done with the engine in or out of the vehicle.

REMOVAL
1. Disconnect negative cable from battery.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

2. Drain the coolant and disconnect the hoses at the engine thermostat housing. DO NOT waste reusable coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.
3. Remove the air cleaner assembly.
4. Remove the engine cylinder head cover.

Rocker Arm Assembly:

5. Remove the capscrews, bridge and pivot assemblies and rocker arms.
6. Remove the push rods. Retain the push rods, bridges, pivots and rocker arms in the same order as removed.
7. Loosen the accessory drive belt at the power steering pump bracket, if equipped or at the idler pulley bracket.
8. If equipped with air conditioning, perform the following:
a. Remove the bolts from the A/C compressor mounting bracket and set the compressor aside.
b. Remove the air conditioner compressor bracket bolts from the engine cylinder head.
c. Loosen the through bolt at the bottom of the bracket.
9. If equipped, disconnect the power steering pump bracket. Set the pump and bracket aside. DO NOT disconnect the hoses.
10. Perform fuel pressure release procedure.
11. Remove the latch clip and disconnect the fuel supply hose.
12. Remove the intake and engine exhaust manifolds from the engine cylinder head.
13. Number and disconnect the ignition wires and remove the spark plugs.
14. Disconnect the coolant temperature sending unit connector.
15. Remove the engine cylinder head bolts.

Engine Cylinder Head Assembly:

16. Remove the engine cylinder head and gasket.
17. If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn't known if they were used before, discard the bolts.
18. Stuff clean lint free shop towels into the cylinder bores.

NOTE: If valves, springs, or seals are to be inspected/replaced at this time, refer to Valves and Valve Springs.

INSTALLATION
The engine cylinder head gasket is a composition gasket. The gasket is to be installed DRY. DO NOT use a gasket sealing compound on the gasket.
If the engine cylinder head is to be replaced and the original valves used, measure the valve stem diameter. Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are reamed to accommodate oversize valve stems. Remove all carbon buildup and reface the valves.

Fabricate Alignment Dowels:

1. Fabricate two engine cylinder head alignment dowels from used head bolts. Use the longest head bolt. Cut the head of the bolt off below the hex head. Then cut a slot in the top of the dowel to allow easier removal with a screwdriver.

Alignment Dowel Locations:

2. Install one dowel in bolt hole No.10 and the other dowel in bolt hole No.8.
3. Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil.
4. Place the engine cylinder head gasket (with the numbers facing up) over the dowels.
5. Place the engine cylinder head over the dowels.

CAUTION: Engine cylinder head bolts should be reused only once. Replace the head bolts if they were used before or if they have a paint dab on the top of the bolt.

6. Coat the threads of bolt No.7, only, with Loctite PST sealant or equivalent.
7. Install all head bolts, except No.8 and No.10.
8. Remove the dowels.
9. Install No.8 and No.10 head bolts.

CAUTION: During the final tightening sequence, bolt No.7 will be tightened to a lower torque than the rest of the bolts. DO NOT overtighten bolt No.7.

Engine Cylinder Head Bolt Tightening Sequence:

10. Tighten the engine cylinder head bolts in sequence according to the following procedure:
a. Tighten all bolts in sequence (1 through 10) to 30 Nm (22 ft. lbs.) torque.
b. Tighten all bolts in sequence (1 through 10) to 61 Nm (45 ft. lbs.) torque.
c. Check all bolts to verify they are set to 61 Nm (45 ft. lbs.) torque.
d. Tighten bolts (in sequence):
^ Bolts 1 through 6 to 149 Nm (110 ft. lbs.) torque.
^ Bolt 7 to 136 Nm (100 ft. lbs.) torque.
^ Bolts 8 through 10 to 149 Nm (110 ft. lbs.) torque.
e. Check all bolts in sequence to verify the correct torque.
f. If not already done, clean and mark each bolt with a dab of paint after tightening. Should you encounter bolts which were painted in an earlier service operation, replace them.
11. Connect the coolant temperature sending unit connector.
12. Install the spark plugs and tighten to 37 Nm (27 ft. lbs.) torque. Connect the ignition wires.
13. Install the intake and exhaust manifolds.
14. Install the fuel supply line. Push until a "click" is heard. Reinstall latch clip.
15. If equipped, attach the power steering pump and bracket.
16. Install the push rods, rocker arms, pivots and bridges in the order they were removed.
17. Install the engine cylinder head cover.
18. Attach the air conditioning compressor mounting bracket to the engine cylinder head and block. Tighten the bolts to 40 Nm (30 ft. lbs.) torque.
19. Attach the air conditioning compressor to the bracket. Tighten the bolts to 27 Nm (20 ft. lbs.) torque.

CAUTION: The accessory drive belt must be routed correctly. Incorrect routing can cause the water pump to turn in the opposite direction causing the engine to overheat.

20. Install the accessory drive belt and correctly tension the belt.
21. Install the air cleaner and ducting.
22. Connect the hoses to the thermostat housing and fill the cooling system to the specified level.
23. Install the coolant temperature sending unit connector.
24. Connect negative cable to battery.
25. Connect the upper radiator hose and heater hose at the thermostat housing.
26. Fill the cooling system. Check for leaks.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH THE FAN. DO NOT PUT HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

27. Operate the engine with the radiator cap off. Inspect for leaks and continue operating the engine until the thermostat opens. Add coolant, if required.