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 negative battery cable from the battery.
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the radiator fan upper shroud. Refer to Fan Shroud Replacement 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 in Engine Controls.
6. Remove the drive belt. Refer to Drive Belt Replacement .
7. Remove the fan blade clutch. Refer to Fan Clutch Replacement in Engine Cooling.



8. Remove the lower intake manifold from the cylinder heads. Refer to the appropriate procedure:

•	Intake Manifold Replacement (L57)

•	Intake Manifold Replacement (L65)

9. Remove the radiator inlet hose from the water outlet. Refer to Radiator Hose Replacement in Engine Cooling.
10. Disconnect the coolant bypass hose.
11. Remove the heater hose from the thermostat crossover housing. Refer to Heater Hoses Replacement in HVAC Systems with A/C -- Manual.



12. Remove the thermostat housing from the cylinder heads. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
13. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C -- Manual.
14. Remove the power steering pump from the mounting bracket. Refer to Power Steering Pump Replacement in Steering Systems.



15. Remove the power steering pump mounting bracket.



16. Remove the glow plugs and the shields from the cylinder head. Refer to the appropriate procedure in Engine Controls:

•	Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side (L65)

•	Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side (L57)




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 shaft from the cylinder head. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .



21. Remove the 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 mounting bolt and the stud from the rear water jacket cover.
26. Remove the rear water jacket cover and the 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 gasket is manufactured with the proper amount of sealant printed on the surface. Additional sealer may cause leakage or a malfunction. 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 the bolts in sequence.

Tighten

1. Tighten the cylinder head bolts to 25 N·m (20 lb ft) in sequence (1-17).
2. Tighten the bolts to 75 N·m (55 lb ft) in sequence (1-17).
3. Retighten the bolts to 75 N·m (55 lb ft) in sequence (1-17).
4. Tighten the bolts an additional 90 to 100 degrees (1/4 + turn) in sequence.



3. Install the rear water jacket cover and the gasket to the cylinder head.
4. Install the rear 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 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 thermostat crossover housing to the cylinder heads. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
9. Install the coolant bypass hose.



10. Install the power steering pump mounting bracket.
11. Install the power steering pump to the mounting bracket. Refer to Power Steering Pump Replacement in Steering Systems.
12. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C -- Manual.



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 stud to 42 N·m (31 lb ft).




15. Install the glow plugs and the shields to the cylinder head. Refer to the appropriate procedure in Engine Controls:

•	Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side (L65)

•	Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side (L57)




16. Install the thermostat housing to the cylinder heads. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
17. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement in Engine Cooling.
18. Install the heater hose to the thermostat crossover housing. Refer to Heater Hoses Replacement in HVAC Systems with A/C -- Manual.



19. Install the lower intake manifold to the cylinder head. Refer to the appropriate procedure:

•	Intake Manifold Replacement (L65)

•	Intake Manifold Replacement (L57)




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 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 in Engine Controls.
24. Install the radiator fan upper shroud. Refer to Fan Shroud Replacement in Engine Cooling.
25. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
26. Connect the negative battery cable.