Special Tools

J 45059 Angle Meter

1. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the heater outlet pipe. Refer to Heater Outlet Pipe Replacement.



3. Remove the nut securing the hose/pipe retainer to the right cylinder head.
4. Remove the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement.



5. Remove the ignition control module and bracket (1). Refer to Ignition Control Module Bracket Replacement.
6. Remove the ignition control module bracket studs (5).
7. Remove the engine right side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement.
8. Remove the engine right side spark plugs. Refer to Spark Plug Replacement.
9. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal - Right Side.
10. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement.
11. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement.
12. Remove the engine right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.
13. Remove the generator bracket and engine lift bracket. Refer to Generator Bracket and Engine Lift Bracket Replacement.



14. Remove the cylinder head bolts and discard.
15. Remove the cylinder head.



16. Remove the cylinder head gasket.

Note: All gasket mating surfaces must remain free of oil and foreign material. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number to use to clean surfaces.

17. Clean the following areas:

•	The gasket sealing surfaces on the cylinder head, cylinder block, intake manifold, and exhaust manifold

•	The cylinder block bolt threads

1. Install the cylinder head gasket.



2. Install the cylinder head.

Caution: Refer to Fastener Caution in the Preface section.





Caution: This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

3. Install the NEW cylinder head bolts.

Tighten the bolts in sequence to 60 N·m (44 lb ft). Turn the bolts an additional 95 degrees using the J 45059 .

4. Install the generator bracket and engine lift bracket. Refer to Generator Bracket and Engine Lift Bracket Replacement.
5. Install the engine right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.
6. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement.
7. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement.
8. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal - Right Side.
9. Install the engine left side spark plugs. Refer to Spark Plug Replacement.
10. Install the engine left side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement.



11. Install the ignition module bracket studs (5) and tighten to 25 N·m (18 lb ft).
12. Install the ignition control module and bracket (1). Refer to Ignition Control Module Bracket Replacement.
13. Install the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement.



14. Install the nut securing the hose/pipe retainer to the right cylinder head and tighten the nut to 25 N·m (18 lb ft).
15. Install the heater outlet pipe. Refer to Heater Outlet Pipe Replacement.
16. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling.