Cylinder Head

Removal & Installation

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the drive belt.
3. Recover the A/C system.
4. Loosen the bolt and separate the A/C manifold tube from the A/C compressor.
5. Disconnect the electrical connector for the A/C compressor.
6. Move the A/C compressor mounting bracket to the side.
7. Disconnect the electrical connectors for the generator.
8. Disconnect the heater hose retaining clip and move the heater water hose to the side.
9. Remove the generator mounting bracket.
10. Remove the lower intake manifold.
11. Remove the right-hand and left-hand exhaust manifolds.

    CAUTION
    The rocker arm shaft can bend during removal if it is not loosened gradually.

12. Carefully remove the rocker arm shafts on the right and left sides.

    NOTE: To ensure correct installation, mark the push rod positions before removal.

13. Remove the push rods.
14. Remove the cylinder heads and gaskets.

To Install:

1. Clean and examine all sealing surfaces.

   NOTE: Cylinder head bolts are torque-to-yield designed, so new bolts must be installed.

   NOTE: The head gaskets are marked for use on either the right side or the left side. They are not interchangeable.

2. Install the cylinder head, gasket, and new bolts. Tighten in the following sequence:
   • Step 1: Tighten to 25 ft-lb (34 Nm).
   • Step 2: Tighten to 53 ft-lb (72 Nm).
   • Step 3: Tighten an extra 90 degrees.

   Cylinder head bolt torque sequence (4.0L)

3. Install the push rods.

   CAUTION
   The rocker arm shaft can bend during installation if it is not tightened gradually.

4. Install the rocker arm and shaft assembly then tighten the bolts in two steps.
   • Step 1: Torque to 24 ft-lb (33 Nm).
   • Step 2: Tighten an extra 90 degrees.
5. Install the exhaust manifolds on the right and left sides.
6. Install the lower intake manifold.
7. Install the generator mounting bracket. Torque to 35 ft-lb (47 Nm).
8. Connect the heater hose retaining clip.
9. Connect the electrical connectors for the generator.
10. Install the A/C compressor mounting bracket. Torque to 35 ft-lb (47 Nm).
11. Connect the electrical connector for the A/C compressor.
12. Install the A/C manifold tube to the A/C compressor. Torque to 15 ft-lb (20 Nm).
13. Recharge the A/C system.
14. Install the drive belt.