Head gasket replacement instructions please?

Based on what you said, there are a couple things that jump out. First, if the head was not not torqued properly then it could push the head gasket out again. Next if the cracked radiator caused an overheat then it could have warped the head and pushed it out again. The other thing that I am thinking is if the head was warped and they did not machine it "enough" to get the warp out.

Then again, this could just be an unfortunate series of events. I don't see enough especially after a year that this would directly implicate the shop that did it.

I would definitely replace the head at this point because I am sure you will not have enough material to machine it again. Plus, I am sure the head is warped. It would be a good idea to straight edge the head and block just to make sure they are okay. If the head is warped then that would explain why it happened. If it is not, then we may need to dig deeper as to other causes of a failed head gasket.

Let me know if you have questions. Thanks

You are welcome. Just so I am clear, you were thinking the AC issue was an indication that the head gasket was going to fail? I just want to make sure I understand the timeline. Thanks

If oil adn "other" ar ecoming out of #1, you are probably going to have to take the head back off to see why it is leaking fluids into the cylinder. May be an incorrect head gasket or a cracked block possibly if you had the head pressure tested adn surfaced and it was good. Did you torque the head according to spec?

Timing wont make it blow fluid out of the cylinder. Have to wait to see what they find, sure sounds like the wrong gasket if it is blowing oil and coolant out of it, assuming that is what you meant by "fluids"

REMOVAL:

Disconnect the negative battery cable.
Drain and recycle the engine coolant.
Drain and recycle the engine oil.
Properly relieve the fuel system pressure.
Disconnect the air duct from the throttle body.
Disconnect the intake manifold braces from the rear of the engine.
Remove the exhaust manifold.
Remove the alternator and all related brackets.
Remove the distributor assembly.
Using a block of wood, set a jack under the aluminum oil pan and remove the passenger's side engine mount.
Remove the cylinder head cover.
Remove the timing chain and camshaft sprockets.

The lower timing chain should not be disengaged from the crankshaft sprocket.

Remove the camshafts.

The valve train components must be reassembled in their original positions. Be sure to note their locations.

Loosen the cylinder head bolts in the illustrated order.

A warped or cracked cylinder head could result from loosening in incorrect order. The cylinder head bolts should be loosened in two or three steps.

Remove the cylinder head and intake manifold as an assembly.
Remove the cylinder head gasket.

INSTALLATION:

Clean the gasket mating surfaces thoroughly.
Inspect both the engine block and cylinder head for damage.
Install a new cylinder head gasket. Ensure that the proper side of the gasket is facing up. Each gasket manufacturer will have a slightly different way of telling which side is up. Read the manufacturer's instructions carefully.
Install the cylinder head and temporarily tighten the cylinder head bolts. This is necessary to avoid damaging the cylinder head gasket. Be sure to install washers between the bolts and cylinder head.
Install the upper timing chain and cover.
Tighten the cylinder head bolts in the proper sequence to the following torque specifications:
A.Tighten all the bolts to 22 ft. lbs. (29 Nm).
B.Tighten all the bolts to 10 ft. lbs. (79 Nm).
C.Loosen all the bolts completely.
D.Tighten all the bolts to 18-25 ft. lbs. (25-34 Nm).
E.Turn all the bolts 86-91 degrees clockwise.If an angle wrench is not available, tighten all the bolts to 6-13 ft. lbs. (75-84 Nm).

Install the camshafts.
Install the timing chain and sprockets.
Install the cylinder head cover.
Install the passenger's side engine mount and lower the engine.
Install the distributor assembly.
Install the alternator and all related brackets.
Install the exhaust manifold.
Install the intake manifold braces.
Connect the air duct to the throttle body.
Refill and bleed the cooling system.
Refill the engine with the proper grade and viscosity of engine oil.
Connect the negative battery cable.
Start the engine and make the necessary adjustments.
Check for proper operation and leaks.