Tools Required
J 36660-A Torque Angle
Meter
Removal Procedure
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Remove the engine cooling fan clutch. Refer to
Fan Clutch Replacement
in Engine Cooling.
- Remove the engine drive belt. Refer to
Drive Belt Replacement
.
- Remove the fan pulley.
- Remove the generator. Refer to
Generator Replacement
in Engine Electrical.
- Remove the A/C compressor, if equipped. Refer to
Air Conditioning Compressor Replacement
in Heating, Ventilation and Air Conditioning.
- Remove the power steering pump. Refer to
Power Steering Pump Replacement
in Power Steering System.
- Remove the thermostat assembly. Refer to
Engine Coolant Thermostat Replacement
in Engine Cooling.
- Remove the bolts holding
the accessory mounting bracket to the engine.
- Remove the accessory mounting bracket.
- Remove the exhaust manifold. Refer to
Exhaust Manifold Replacement
in Engine Exhaust.
- Remove the valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Remove the valve rocker arms and push rods. Refer to
Valve Rocker Arm and Push Rod Replacement
.
- Remove the intake manifold. Refer to
Intake Manifold Replacement
.
- Remove the engine lift
bracket from the rear of the engine.
- Remove the cylinder head
bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
- Clean the following areas:
• | Clean any carbon deposits from the combustion chambers. |
• | Clean all traces of the old cylinder head gasket from the cylinder
head and from the engine block. |
| Important: Do not use abrasive pads to clean the cylinder head or block surfaces.
An abrasive pad will damage the cylinder head and block surfaces. Abrasive
pads also produce a fine grit that will contaminate the engine oil.
It is only necessary to remove the gasket material. Do not attempt to
remove all marks from the cylinder head gasket surfaces.
|
• | Clean the cylinder head bolt threads. |
• | Clean the threads that are in the engine block. |
- Inspect the engine block to cylinder head mating surface for the
following conditions:
• | For further service to the cylinder head refer to the following: |
• | in Engine Mechanical - 2.2L Unit Repair |
Installation Procedure
Important: Install the NEW cylinder head gasket with the words THIS SIDE UP showing.
- Install the cylinder head gasket to the block.
- Use a socket to push the cylinder head gasket over the rear dowel
pin.
- Carefully guide the cylinder
head into place over the dowel pins. This operation may require an assistant.
- Install the cylinder head
bolts by hand.
- Use the following sequence
in order to tighten the cylinder head bolts:
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
Tighten
• | Tighten the long cylinder head bolts to 63 N·m (46 lb ft). |
• | Tighten the short cylinder head bolts to 58 N·m (43 lb ft). |
5.1. | Tighten bolt 1 to 63 N·m (46 lb ft). |
5.2. | Tighten bolt 2 to 58 N·m (43 lb ft). |
5.3. | Tighten bolt 3 to 58 N·m (43 lb ft). |
5.4. | Tighten bolt 4 to 63 N·m (46 lb ft). |
5.5. | Tighten bolt 5 to 63 N·m (46 lb ft). |
5.6. | Tighten bolt 6 to 58 N·m (43 lb ft). |
5.7. | Tighten bolt 7 to 58 N·m (43 lb ft). |
5.8. | Tighten bolt 8 to 63 N·m (46 lb ft). |
5.9. | Tighten bolt 9 to 63 N·m (46 lb ft). |
5.10. | Tighten bolt 10 to 58 N·m (43 lb ft). |
5.11. | Use J 36660-A
to
tighten all the cylinder head bolts an additional 90 degrees in sequence. |
- Install the engine lift
bracket onto the rear of the engine.
Tighten
Tighten the engine lift bracket nut to 50 N·m (37 lb ft).
- Install the intake manifold. Refer to
Intake Manifold Replacement
.
- Install the valve rocker arms and push rods. Refer to
Valve Rocker Arm and Push Rod Replacement
.
- Install the valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
.
- Install the exhaust manifold. Refer to
Exhaust Manifold Replacement
in Engine Exhaust.
- Install the accessory
mounting bracket.
- Install the bolts holding the accessory mounting bracket to the
engine.
Tighten
Tighten the accessory mounting bolts to 50 N·m (37 lb ft).
- Install the thermostat assembly. Refer to
Engine Coolant Thermostat Replacement
in Engine Cooling.
- Install the A/C compressor, if equipped. Refer to
Air Conditioning Compressor Replacement
in Heating, Ventilation and Air Conditioning.
- Install the power steering pump. Refer to
Power Steering Pump Replacement
in Power Steering System.
- Install the generator. Refer to
Generator Replacement
in Engine Electrical.
- Install the fan pulley.
Tighten
Tighten the fan pulley bolts to 30 N·m (22 lb ft).
- Install the engine drive belt. Refer to
Drive Belt Replacement
.
- Install the engine cooling fan clutch. Refer to
Fan Clutch Replacement
in Engine Cooling.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.