Disconnect the negative battery cable.
Drain the cooling system.
Disconnect the hoses at the thermostat housing.
Properly relieve the fuel system pressure.
Remove the cylinder head cover.
Loosen the rocker arms.
Remove the pushrods.
The valvetrain components must be replaced in their original positions.
Remove the intake and exhaust manifold from the cylinder head.
Disconnect the spark plug wires and remove the spark plugs.
Disconnect the temperature sending unit wire, ignition coil and bracket assembly from the engine.
Remove the accessory drive belt(s).
Unbolt and set aside the power steering pump and bracket. Do not disconnect the hoses.
Remove the intake and exhaust manifold assembly.
If equipped with A/C, perform the following:
Remove the compressor and position it aside with the lines attached.
Remove the compressor bracket bolts from the cylinder head.
Loosen the through bolt at the bottom of the bracket.
Remove the alternator.
Remove the cylinder head bolts, the cylinder head and gasket from the block.
Bolt No. 14 cannot be removed until the head is moved forward. Pull the bolt out as far as it will go and suspend in place by wrapping with tape.
Discard the gasket. Thoroughly clean the head-to-block mating surface.
Clean and inspect the cylinder head thoroughly. Refer to the engine reconditioning portion outlined later in this section.
Coat a new head gasket with suitable sealing compound and place it on the block. Most replacement gaskets will have the word TOP stamped on them.
Apply sealing compound only to the cylinder head gasket. Do not allow sealing compound to enter the cylinder bore.
The 1991-98 cylinder head gaskets used on the 4.0L are a composition gasket. The gasket is to be installed DRY. DO NOT use sealing compound.
Install the cylinder head and bolts. The threads of bolt No. 11 must be coated with Loctite® 592 sealant before installation. Tighten the bolts in 3 steps, using the correct sequence:
Tighten all bolts to 22 ft. lbs. (30 Nm).
Tighten all bolts to 45 ft. lbs. (61 Nm).
Retighten all bolts to 45 ft. lbs. (61 Nm).
Tighten bolts 1 through 10 in sequence to 110 ft. lbs. (150 Nm).
Tighten bolt 11 to 100 ft. lbs. (136 Nm)
Tighten bolts 12 through 14 to 110 ft. lbs. (150 Nm)
Cylinder head bolts should be reused only once. Replace the head bolts which were previously used or are marked with paint. If head bolts are to be reused, mark each head bolt with paint for future reference. Head bolts should be installed using sealer.
Install the ignition coil.
Install the air conditioning compressor.
Install the alternator.
Install the intake and exhaust manifold assembly.
Install the power steering pump and bracket.
Install the accessory drive belt(s).
Connect the temperature sending unit wire, ignition coil and bracket.
Install the spark plugs and wires.
Install the pushrods, rocker arm assembly, gasket and cylinder head cover.
Connect the hoses at the thermostat housing.
Fill the cooling system.
Connect the negative battery cable.
Run the engine to normal operating temperature and check for leaks.
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