1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
4. Remove the drive belts from the pulleys. Refer to Drive Belt Replacement .
5. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
6. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
7. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .
8. Remove the lower intake manifold from the cylinder head. Refer to Intake Manifold Replacement .
9. Remove the turbocharger from the engine block. Refer to Turbocharger .
10. Remove the valve rocker arm covers from the cylinder head. Refer to Valve Rocker Arm Cover Replacement .
11. Remove the valve rocker arm assemblies and the push rods. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
12. Remove the radiator hoses from the vehicle. Refer to Radiator Hose Replacement .
13. Remove the thermostat housing from the cylinder heads. Refer to Engine Coolant Thermostat Removal .
14. Remove the exhaust manifolds from the cylinder heads. Refer to Exhaust Manifold Removal .
15. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C-Manual.
16. Remove the A/C mounting bracket and secure to the side.
17. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
18. Remove the generator mounting bracket from the cylinder head and secure to the side. Refer to Generator Bracket Replacement in Engine Electrical.
19. Remove the wire harness and electrical connectors; move aside.
20. Remove the cylinder head bolts (in sequence from the cylinder head).



21. Remove the cylinder heads from the engine block.
22. Disassemble the cylinder head assembly. Refer to Cylinder Head Disassemble .

Important: Do not use a sealer on the head gasket. The head gasket is manufactured with the proper amount of sealant "printed" on its surface. Additional sealer may cause leakage or malfunction. In addition, some sealers may attack the sealant already on the head gasket.

1. Assemble the cylinder head assembly. Refer to Cylinder Head Assemble .
2. Install the head gasket to the block over the dowel pins.



3. Install the cylinder head to the engine block.



4. Install the cylinder head bolts in the cylinder heads.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the cylinder head bolts to the cylinder head (in sequence) and tighten in 4 passes.

Tighten

1. Bolts to 25 N·m (20 lb ft).
2. Bolts to 75 N·m (55 lb ft).
3. Retighten bolts to 75 N·m (55 lb ft).
4. In sequence, tighten all bolts an additional 90-100 degrees (1/4 + turn).
6. Install the push rods and the valve rocker arm to the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
7. Install the valve rocker arm cover to the cylinder head. Refer to Valve Rocker Arm Cover Replacement .
8. Install the generator mounting bracket to the cylinder head. Refer to Generator Bracket Replacement .
9. Install the A/C mounting bracket to the front of the engoine assembly.
10. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Installation .
11. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
12. Install the turbocharger assembly to the engine block. Refer to Turbocharger .
13. Install the thermostat housing assembly to the cylinder head. Refer to Engine Coolant Thermostat Removal .
14. Install the radiator hoses in the vehicle. Refer to Radiator Hose Replacement in Engine Cooling.
15. Install the lower intake manifold to the cylinder head. Refer to Intake Manifold Replacement .
16. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement .
17. Install the wiring harness, electrical connectors and brackets.
18. Install the air conditioning compressor mounting bracket. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C--Manual.
19. Install the fan clutch to the water pump assembly. Refer to Fan Clutch Replacement in Enginew Cooling.
20. Install the drive belt on the pulleys. Refer to Drive Belt Replacement .
21. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
22. Install the engine cover to the vehicle. Refer to Engine Cover Replacement in Interior Trim.
23. Fill the cooling system with the proper quantity and grade of coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
24. Connect the battery negative cables to the batteries. Refer to Battery Cable Replacement in Engine Electrical.