Cylinder Head Replacement Left

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in Engine Electrical.
2. Drain the cooling system. Refer to Draining and Filling Cooling System .
3. Remove the radiator fan upper shroud. Refer to Fan Shroud Replacement (Lower VIN 1) in Engine Cooling.



4. Remove the upper intake manifold from the lower intake manifold (L65 only). Refer to Intake Manifold Replacement .
5. Remove the air cleaner assembly (L56 only). Refer to Air Cleaner Element Replacement (EFI/MFI) in Engine Controls.
6. Remove the drive belt. Refer to Drive Belt Replacement .
7. Remove the fan blade clutch. Refer to Fan Clutch Replacement (Diesel) in Engine Cooling.



8. Remove the lower intake manifold from the cylinder heads.

•	For the L57 intake manifold removal, refer to Intake Manifold Replacement (Lower) .

•	For the L65 intake manifold removal, refer to Intake Manifold Replacement .

9. Remove the radiator inlet hose from the water outlet. Refer to Radiator Hose Replacement .
10. Disconnect the coolant bypass hose.
11. Remove the heater hose from the thermostat crossover housing. Refer to Heater Hoses Replacement in HVAC.



12. Remove the thermostat housing (4) from the cylinder heads. Refer to Thermostat Housing Crossover Replacement (Diesel) .
13. Remove the air conditioning compressor. Refer to Compressor Replacement (6.5L) in HVAC.
14. Remove the power steering pump from the power steering pump mounting bracket. Refer to Power Steering Pump Replacement (6.5L Diesel Engine) in Steering Systems.



15. Remove the power steering pump mounting bracket. Refer to Accessory Brackets Replacement .



16. Remove the glow plugs and the shields from the cylinder head.

•	For the L65, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side

•	For the L57, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side




17. Remove the left exhaust manifold from the cylinder head. Refer to Exhaust Manifold Replacement .
18. Remove the crankcase vent tube stud from the rear of the left cylinder head.



19. Remove the valve rocker arm cover from the cylinder head. Refer to Valve Rocker Arm Cover Replacement .



20. Remove the valve rocker arm and shaft from the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



21. Remove to push rods from the engine block. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
22. Remove the cylinder head bolts from the engine block.
23. Remove the cylinder head from the engine block.



24. Remove the cylinder head gasket from the engine block.



25. Remove the rear cylinder head water jacket cover mounting bolt and stud.
26. Remove the rear cylinder head water jacket cover and gasket from the cylinder head.
27. Inspect the sealing surfaces of the engine block. Refer to Engine Block Clean and Inspect .

Important: The engine block surfaces must be clean. Do not use a sealer on the cylinder head gaskets. The cylinder head gaskets are manufactured with the proper amount of sealant Printed on their surface. Additional sealer may cause leakage or a malfunction. In addition, some sealers may attack the sealant already on the cylinder head gasket.

Important: The cylinder head gasket material is soft. Handle the cylinder head gasket with care and make sure that the sealing surfaces are not damaged.

1. Install the cylinder head gasket to the engine block.




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.

2. Install the cylinder head bolts and tighten in sequence.

Tighten

1. In sequence (1-17), tighten all of the cylinder head bolts to 25 N·m (20 lb ft).
2. In sequence (1-17), tighten all of the bolts to 75 N·m (55 lb ft).
3. In sequence (1-17), retighten all of the bolts to 75 N·m (55 lb ft).
4. In sequence, tighten all of the bolts an additional 90 to 100 degrees (1/4 + turn).



3. Install the rear cylinder head water jacket cover and gasket to the cylinder head.
4. Install the rear cylinder head water jacket cover mounting bolt and stud.

Tighten
Tighten the bolt/stud to 42 N·m (31 lb ft).




5. Install the push rods into the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



6. Install the valve rocker arm and shaft to the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



7. Install the valve rocker arm covers to the cylinder head. Refer to Valve Rocker Arm Cover Replacement .
8. Install the thermostat crossover housing to the cylinder heads. Refer to Thermostat Housing Crossover Replacement (Diesel) .
9. Install the coolant bypass hose.



10. Install the power steering pump mounting bracket. Refer to Accessory Brackets Replacement .
11. Install the power steering pump to the power steering pump mounting bracket. Refer to Power Steering Pump Replacement (6.5L Diesel Engine) in Steering Systems.
12. Install the air conditioning compressor. Refer to Compressor Replacement (6.5L) in HVAC.



13. Install the left exhaust manifold to the cylinder head. Refer to Exhaust Manifold Replacement .
14. Install the crankcase vent tube stud to the rear of the left cylinder head.

Tighten
Tighten the crankcase vent tube stud to 42 N·m (31 lb ft).




15. Install the glow plugs and the shields to the cylinder head.

•	For the L65, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side

•	For the L57, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side




16. Install thermostat housing to the cylinder heads. Refer to Thermostat Housing Crossover Replacement (Diesel) .
17. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement .
18. Install the heater hose to the thermostat crossover housing. Refer to Heater Hoses Replacement in HVAC.



19. Install the lower intake manifold to the cylinder heads.

•	For the L57 intake manifold, refer to Intake Manifold Replacement (Lower)

•	For the L65 intake manifold, refer to Intake Manifold Replacement




20. Install the upper intake manifold to the lower intake manifold (L65 only). Refer to Intake Manifold Replacement .
21. Install the fan blade clutch. Refer to Fan Clutch Replacement (Diesel) in Engine Cooling.
22. Install the drive belt. Refer to Drive Belt Replacement .
23. Install the air cleaner assembly (L56 only). Refer to Air Cleaner Element Replacement (EFI/MFI) in Engine Controls.
24. Install the radiator fan upper shroud. Refer to Fan Shroud Replacement (Lower VIN 1) in Engine Cooling.
25. Fill the cooling system. Refer to Draining and Filling Cooling System .
26. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement .

Cylinder Head Replacement Right

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement .
2. Drain the cooling system. Refer to Draining and Filling Cooling System .
3. Remove the radiator fan upper shroud. Refer to Fan Shroud Replacement (Lower VIN 1) in Engine Cooling.



4. Remove the upper intake manifold from the lower intake manifold (L65 only). Refer to Intake Manifold Replacement .

Remove the air cleaner assembly (L57 only). Refer to Air Cleaner Element Replacement (EFI/MFI) in Engine Controls.

5. Remove the fan blade clutch. Refer to Fan Clutch Replacement (Diesel) in Engine Cooling.
6. Remove the drive belt. Refer to Drive Belt Replacement .



7. Remove the lower intake manifold from the cylinder heads.

•	For the L57 intake manifold removal, refer to Intake Manifold Replacement (Lower) .

•	For the L65 intake manifold removal, refer to Intake Manifold Replacement .

8. Remove the radiator inlet hose from the water outlet. Refer to Radiator Hose Replacement .
9. Remove the heater hose from the thermostat housing crossover. Refer to Heater Hoses Replacement in HVAC.
10. Remove the thermostat housing crossover from the cylinder heads. Refer to Thermostat Housing Crossover Replacement (Diesel) .



11. Remove the turbocharger assembly from the exhaust manifold (L65 only). Refer to Turbocharger Replacement .
12. Remove the CDR valve from the right valve rocker arm cover.
13. Remove the engine wiring harness from the rear of the right valve cover and move to the side.



14. Remove the glow plugs and the shields from the cylinder head.

•	For the L65, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side

•	For the L57, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side




15. Remove the right exhaust manifold from the cylinder head. Refer to Exhaust Manifold Replacement .
16. Remove the generator. Refer to Generator Replacement (Diesel Engines) in Engine Electrical.



17. Remove the vacuum pump. Refer to Vacuum Pump Replacement .
18. Remove the generator mounting bracket. Refer to Accessory Brackets Replacement .
19. Remove the ground strap from the rear of the cylinder head.



20. Remove the valve rocker arm cover from the cylinder head. Refer to Valve Rocker Arm Cover Replacement .



21. Remove the valve rocker arm and shaft from the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



22. Remove the push rods from the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



23. Remove the cylinder head bolts from the engine block.
24. Remove the cylinder head from the engine block.
25. Remove the cylinder head gasket from the engine block.



26. Remove the rear cylinder head water jacket cover mounting bolts and studs.
27. Remove the rear cylinder head water jacket cover and gasket from the cylinder head.
28. Inspect the sealing surfaces of the engine block. Refer to Engine Block Clean and Inspect .

Important: The engine block surfaces must be clean. Do not use a sealer on the cylinder head gaskets. The cylinder head gaskets are manufactured with the proper amount of sealant Printed on their surface. Additional sealer may cause leakage or a malfunction. In addition, some sealers may attack the sealant already on the cylinder head gasket.

Important: The cylinder head gasket material is soft. Handle the cylinder head gasket with care and make sure that the sealing surfaces are not damaged.

1. Install the cylinder head gasket to the engine block.




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.

2. Install the cylinder head bolts and tighten in sequence.

Tighten

1. In sequence (1-17), tighten the bolts to 25 N·m (20 lb ft).
2. In sequence (1-17), tighten the bolts to 75 N·m (55 lb ft).
3. In sequence (1-17), retighten the bolts to 75 N·m (55 lb ft).
4. Tighten all bolts an additional 90 to 100 degrees (1/4 + turn).



3. Install the rear cylinder head water jacket cover and gasket to the cylinder head.
4. Install the rear cylinder head water jacket cover mounting bolt and stud.

Tighten
Tighten the bolt and stud to 42 N·m (31 lb ft).




5. Install the push rods into the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



6. Install the valve rocker arm and shaft 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. Refer to Accessory Brackets Replacement .



9. Install the vacuum pump to the accessory mounting bracket. Refer to Vacuum Pump Replacement .
10. Install the generator to the mounting bracket. Refer to Generator Replacement (Diesel Engines) in Engine Electrical.



11. Install the right exhaust manifold to the cylinder head. Refer to Exhaust Manifold Replacement .



12. Install the glow plugs and the shields to the cylinder head.

•	For the L65, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side

•	For the L57, refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side




13. Install the turbocharger assembly to the exhaust manifold (L65 only). Refer to Turbocharger Replacement .
14. Install the CDR valve to the right valve rocker arm cover.
15. Install the engine wiring harness to the right rear of the valve rocker arm cover.
16. Install the coolant bypass hose.



17. Install thermostat housing crossover to the cylinder heads. Refer to Thermostat Housing Crossover Replacement (Diesel) .
18. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement .
19. Refill the cooling system. Refer to Draining and Filling Cooling System .
20. Install the radiator fan upper shroud. Refer to Fan Shroud Replacement (Lower VIN 1) in Engine Cooling.



21. Install the lower intake manifold to the cylinder heads.

•	For the L57 intake manifold, refer to Intake Manifold Replacement (Lower)

•	For the L65 intake manifold, refer to Intake Manifold Replacement




22. Install the upper intake manifold to the lower intake manifold (L65 only). Refer to Intake Manifold Replacement .
23. Install the drive belt. Refer to Drive Belt Replacement
24. Install the fan blade clutch. Refer to Fan Clutch Replacement (Diesel) in Engine Cooling.
25. Install the air cleaner assembly (L57 only). Refer to Air Cleaner Element Replacement (EFI/MFI) in Engine Controls.
26. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement .