Special Tools

J 45059 Angle Meter

1. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
2. Remove the power steering pump bolts and reposition the power steering pump.
3. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
4. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



5. Remove the exhaust gas recirculation (EGR) valve nuts.
6. Remove the EGR valve.



7. Remove the EGR valve adapter bolts.
8. Remove the EGR valve adapter.



9. Remove and discard the cylinder head bolts.
10. Remove the right cylinder head.



11. Remove the cylinder head gasket.
12. Remove the caps, springs, valves, and seals from the cylinder head. Refer to Cylinder Head Disassemble .
13. Inspect the engine block. Refer to Engine Block Cleaning and Inspection .
14. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .
15. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
16. Clean the cylinder block bolt hole threads.

Notice: Head gaskets are not interchangeable. The head gasket must be installed with the arrow pointing to the front of the engine. Installing the head gasket in any other direction will cause gasket failure and possible engine failure.

1. Install the valves, seals, springs, and caps to the cylinder head. Refer to Cylinder Head Assemble .
2. Position the head gasket with the arrow pointing to the front of the engine.



3. Install the cylinder head.

Notice: Refer to Fastener Notice in the Preface section.

Notice: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.

Notice: This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.




4. Install NEW cylinder head bolts (1-8).

Tighten

•	Tighten the bolts (1-8) in the sequence shown to 50 N·m (37 lb ft).

•	Using the J 45059 rotate the bolts (1-8) in sequence an additional 120 degrees.




5. Install the EGR valve adapter to the right cylinder head.
6. Install the EGR valve adapter bolts to the right cylinder head.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




7. Install the EGR valve.
8. Install the EGR valve nuts.

Tighten
Tighten the nuts to 29 N·m (21 lb ft).




9. Install the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .
10. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
11. Position and install the power steering pump and bolts.

Tighten
Tighten the bolts to 34 N·m (25 lb ft).

12. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .