Tools Required

1. Remove the following subassemblies:

•	The left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.

•	The generator. Refer to Generator Replacement in Engine Electrical.

•	The water crossover. Refer to Engine Coolant Crossover Pipe Replacement in Engine Cooling.

•	The intake manifold. Refer to Intake Manifold Replacement .

•	The camshaft cover. Refer to Camshaft Cover Replacement - Left Side .

•	The engine front cover. Refer to Engine Front Cover Replacement .

•	The left secondary camshaft drive chain. Refer to Secondary Camshaft Drive Chain Replacement - Left Side .




2. Remove the power steering return hose retaining bolt from the cylinder head.



3. Remove the three M6 external drive bolts from the front portion of the cylinder head.

Important: DO NOT reuse the M11 cylinder head bolts.

4. Remove and discard the ten M11 internal drive cylinder head bolts.



5. Remove the left cylinder head. Make sure that no dowel guide pins are stuck in the cylinder head.

Important: You must clean the thread sealant material from the cylinder head bolt holes in the cylinder block. Failure to do so could cause false torque readings during reassembly.

6. After removing the cylinder head, remove any remaining bolt thread sealant material from the threaded cylinder block holes.




Important: DO NOT reuse the cylinder head gasket.

7. Remove the left cylinder head gasket.
8. Remove all remaining gasket material from the cylinder head and cylinder block using the J 28410 .
9. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in order to prevent damage to the deck face.
10. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection in Engine Mechanical - 4.0 L Unit Repair.

1. Make sure all the cylinder head locating pins are securely mounted in the cylinder block deck face.

Important: Failure to remove all the old thread sealant material from the cylinder block could cause false torque readings.

2. Make sure any old thread sealant material is removed from the cylinder head bolt holes in the cylinder block.



3. Install a new left cylinder head gasket using the deck face locating pins for retention.



4. Align the cylinder head with the deck face locating pins.
5. Place the cylinder head in position on the deck face.




Important: DO NOT reuse the old M11 cylinder head bolts.

6. Install new M11 cylinder head bolts in the cylinder head.
7. Install the M6 cylinder head bolts at the front of the cylinder head.




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.

8. Tighten the left cylinder head bolts in the sequence shown.

8.1.	First Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts to 40 N·m(30 lb ft) in the sequence shown.

8.2.	Second Pass

Tighten
Using the J 36660-A , tighten the left cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown.

8.3.	Third Pass

Tighten
Repeat the sequence turning each bolt another 60 degrees.

8.4.	Final Pass

Tighten
Repeat the sequence again turning each bolt a final 45 degrees (total 175 degrees).

9. Tighten the M6 bolts at the front of the cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).




10. Install the power steering return hose retaining bolt to the cylinder head.

Tighten
Tighten the power steering return hose retaining bolt to 50 N·m (37 lb ft).

11. Install the following subassemblies:

•	The left secondary camshaft drive chain. Refer to Secondary Camshaft Drive Chain Replacement - Left Side .

•	The engine front cover. Refer to Engine Front Cover Replacement .

•	The camshaft cover. Refer to Camshaft Cover Replacement - Left Side .

•	The intake manifold. Refer to Intake Manifold Replacement .

•	The water crossover. Refer to Engine Coolant Crossover Pipe Replacement in Engine Cooling.

•	The generator. Refer to Generator Replacement in Engine Electrical.

•	The left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.