Tools Required

J 36660-A Torque/Angle Meter

1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
4. Remove the air cleaner from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L (L65).
5. Remove the air intake duct from the turbocharger.



6. Remove the transmission oil level indicator and tube from the upper intake manifold.
7. Remove the heater hoses from the engine. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
8. Remove the generator mounting bracket. Refer to Generator Bracket Replacement in Engine Electrical.
9. Remove the thermostat housing crossover from the cylinder heads.
10. Remove the turbocharger from the engine block. Refer to Turbocharger Replacement .
11. Remove the right side lower intake manifold from the cylinder head. Refer to Lower Intake Manifold Replacement .
12. Remove the glow plugs from the cylinder head. Refer to Glow Plug Replacement - Bank 2 in Engine Controls-6.5L (L65).
13. Remove the fuel injection nozzles from the cylinder head. Refer to Fuel Injector Replacement in Engine Controls-6.5L (L65).



14. Remove the front lower cylinder head bolt (5) and drain the coolant from the engine block.

14.1.

Insert a cooper tube (3/8 in x 12 in to 18 in) and a hose into bolt hole (5)

14.2.

Siphon coolant from the engine block

15. Remove the valve rocker arms, shafts, and the push rods from the cylinder heads. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
16. Remove the exhaust manifold from the cylinder head. Refer to Exhaust Manifold Replacement - Right Side .
17. Remove the cooper tube used as a siphon from the cylinder head.



18. Remove the remaining cylinder head bolts from the cylinder head in sequence.



19. Remove the cylinder head from the engine block.



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

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.

21. Clean the cylinder block surface and cylinder head bolt holes.
22. For cleaning and inspection procedures refer to the following:

•	Engine Block Cleaning and Inspection

•	Cylinder Head Disassemble

•	Cylinder Head Cleaning and Inspection

•	Valve Guide Reaming, and Valve and Seat Grinding

•	Cylinder Head Assemble

Important: 

•	Make sure that the block gasket surfaces are clean.

•	The head gasket material is soft. Handle the gasket with care. Make sure the gasket surface is not creased or dented.

•	Do not use a sealer on the head gasket. The head gasket is made with sealant on the gasket surface. Additional sealer may cause leakage or malfunction. In addition, some sealers may attack the initial sealant on the gasket.

1. Install the right cylinder head gasket to the block, over the cylinder head dowel pins.



2. Install the right cylinder head to the block, over the cylinder head gasket and the cylinder head dowel pins.



3. Apply the thread sealant GM P/N 12345382, or equivalent, to the bolt threads and under the bolt heads.
4. Install the cylinder head bolts.




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. Tighten the cylinder head bolts in sequence in four passes.

Tighten

1. Tighten the bolts to 25 N·m (20 lb ft).
2. Tighten the bolts to 75 N·m (55 lb ft).
3. Retighten the bolts to 75 N·m (55 lb ft).
4. Using the J 36660-A , tighten all of the cylinder head bolts in sequence (1-17) an additional 90 degrees-100 degrees (1/4 plus turn).
6. Install the glow plugs to the cylinder head. Refer to Glow Plug Replacement - Bank 2 in Engine Controls-6.5L (L65).
7. Install the fuel injection nozzles to the cylinder head. Refer to Fuel Injector Replacement in Engine Controls-6.5L (L65).
8. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Replacement - Right Side .
9. Install the valve rocker arms, shafts, and the push rods to the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
10. Install the generator mounting bracket. Refer to Generator Bracket Replacement in Engine Electrical.
11. Install the heater hoses to the engine. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
12. Install the right side lower intake manifold to the cylinder head. Refer to Lower Intake Manifold Replacement .
13. Install the turbocharger to the engine block. Refer to Turbocharger Replacement .
14. Install the thermostat housing coolant crossover to the cylinder heads.



15. Install the transmission indicator and tube to the engine block.



16. Install the air intake duct to the turbocharger.
17. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L (L65).
18. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
19. Connect the battery negative cables to the batteries. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
20. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Interior Trim.