Special Tools

J 45059 Angle Meter

1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
4. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
5. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
6. Remove the right spark plugs. Refer to Spark Plug Replacement .
7. Remove the fuel line bracket bolt and stud.
8. Remove the fuel line bracket.
9. Remove the generator. Refer to Generator Replacement .



10. Remove and discard the cylinder head bolts.
11. Remove the cylinder head.



12. Remove and discard the cylinder head gasket.
13. Remove the cylinder head locator dowel pins, if necessary.
14. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Notice: Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings (1) on the head gaskets for proper installation. Failure to do so may lead to engine damage.

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.



3. Install a NEW cylinder head gasket.



4. Install the cylinder head onto the locator pins and the engine.

Notice: 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.

5. Install NEW cylinder head bolts finger tight.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the NEW small hex cylinder head bolts (5 and 8).
7. Install the NEW large hex cylinder head bolts (1, 2, 3, 4, 6 and 7).

Tighten

1. Tighten the cylinder head bolts a first pass in sequence to 60 N·m (44 lb ft).
2. Tighten the cylinder head bolts a final pass in sequence to 140 degrees using the J 45059 .
8. Install the generator. Refer to Generator Replacement .



9. Position the fuel line bracket to the cylinder head.
10. Install the fuel line bracket bolt and stud.

Tighten
Tighten the bolt and the stud to 50 N·m (37 lb ft).

11. Install the right spark plugs. Refer to Spark Plug Replacement .
12. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
13. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
14. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .
15. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
16. Inspect for leaks.