Downloaded from www.Manualslib.com manuals search engine place, inspect to make sure seals are in place.
Remove alignment studs if used.
(9) The following torque sequence duplicates the
expected results of the automated assembly system
(Fig. 44).
²Step 1ÐTighten bolts 1 thru 4, in sequence, to 8
N´m (72 in. lbs.) torque. Tighten in alternating steps
1.4 N´m (12 in. lbs.) torque at a time.
²Step 2ÐTighten bolts 5 thru 12, in sequence, to
8 N´m (72 in. lbs.) torque.
²Step 3ÐCheck that all bolts are tightened to 8
N´m (72 in. lbs.) torque.
²Step 4ÐTighten all bolts, in sequence, to 16 N´m
(12 ft. lbs.) torque.
²Step 5ÐCheck that all bolts are tightened to 16
N´m (12 ft. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Install the coil wires.
(12) Connect the coolant temperature sending unit
wire.
(13) Connect the heater hoses and bypass hose.
(14) Install distributor cap and wires.
(15) Connect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel supply line to the fuel rail.
(17) Install the accessory drive bracket and A/C
compressor.(18) Install the generator and accessory drive belt.
Tighten generator mounting bolt to 41 N´m (30 ft.
lbs.) torque.
(19) Install the air cleaner assembly and air inlet
hose.
(20) Fill cooling system.
(21) Connect the battery negative cable.
Fig. 42 Cross-Over Gaskets
1 ± FRONT CROSS-OVER GASKET
2 ± REAR CROSS-OVER GASKET
Fig. 43 Intake Manifold Flange Gasket Alignment
1 ± FLANGE GASKET
2 ± ALIGNMENT TABS
3 ± CYLINDER HEAD GASKET
Fig. 44 Intake Manifold Bolt Tightening SequenceÐ
5.9L Engine
9 - 164 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
Downloaded from www.Manualslib.com manuals search engine CYLINDER HEAD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system Refer to COOLING SYS-
TEM.
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform fuel system pressure release proce-
dure. Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
(15) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust manifolds.
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(19) Remove spark plugs.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N´m (50 ft. lbs.) torque (Fig.
50). Repeat procedure, tighten all cylinder head bolts
to 143 N´m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N´m (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(5) Install the intake manifold and throttle body
assembly.(6) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N´m (25 ft. lbs.) torque.
(7) Adjust spark plugs to specifications. Refer to
IGNITION SYSTEM. Install the plugs and tighten to
41 N´m (30 ft. lbs.) torque.
(8) Install coil wires.
(9) Connect heat indicator sending unit wire.
(10) Connect the heater hoses and bypass hose.
(11) Install distributor cap and wires.
(12) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(13) Install the fuel supply line.
(14) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N´m (30 ft. lbs.)
torque.
(15) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(16) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers. Tighten the
bolts to 11 N´m (95 in. lbs.) torque.
(17) Install closed crankcase ventilation system.
(18) Connect the evaporation control system.
(19) Install the air cleaner assembly and air inlet
hose.
(20) Install the heat shields. Tighten the bolts to
41 N´m (30 ft. lbs.) torque.
(21) Fill cooling system.
(22) Connect the battery negative cable.
VALVES AND VALVE SPRINGS
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
Fig. 50 Cylinder Head Bolt Tightening Sequence
DN5.9L ENGINE 9 - 167
REMOVAL AND INSTALLATION (Continued)
