Tools Required

1. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
2. Remove the engine coolant air bleed pipe and covers. Refer to Coolant Air Bleed Pipe Assembly Replacement .
3. Remove the generator bracket. Refer to Generator Bracket Replacement .
4. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side .
5. Remove the intake manifold. Refer to Intake Manifold Replacement .
6. Remove the engine wiring harness ground bolt from the rear of the left cylinder head.
7. Reposition the engine wire harness ground strap away from the cylinder head.




Important: The cylinder head bolts are NOT reusable.

8. Remove the cylinder head bolts.

Notice: After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

9. Remove the cylinder head.



10. Remove the cylinder head gasket (217).
11. Discard the gasket.
12. Discard all M8 and M11 cylinder head bolts.
13. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Caution: Refer to Safety Glasses Caution in the Preface section.





Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Important: 

•	Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.

•	Do not use any type of sealant on the cylinder head gasket, unless specified.

•	The cylinder head gaskets must be installed in the proper direction and position.

1. Clean the engine block cylinder head bolt holes, if required.

Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.

2. Spray cleaner into the hole. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).



5. Inspect the locating pins for proper installation.



6. Inspect the displacement markings on the gasket for proper usage.



7. Install the NEW cylinder head gasket (217) onto the locating pins.



8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (200, 221).

Notice: Refer to Fastener Notice in the Preface section.




10. Tighten the cylinder head bolts.

Tighten

1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N·m (22 lb ft).
2. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 .
3. Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 .
4. Tighten the M8 cylinder head bolts (11-15) to 30 N·m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
11. Install the intake manifopld. Refer to Intake Manifold Replacement .



12. Position the engine wire harness ground strap against the cylinder head.
13. Install the engine wiring harness ground bolt to the rear of the left cylinder head.

Tighten
Tighten the engine wire harness ground bolt to 32 N·m (24 lb ft).

14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side .
15. Install the generator bracket. Refer to Generator Bracket Replacement .
16. Install the engine coolant air bleed pipe. Refer to Coolant Air Bleed Pipe Assembly Replacement .
17. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .