1. If removed, using a new exhaust manifold gasket, position the exhaust manifold and install the
retaining bolts finger tight.
2. Using the sequence shown in illustration, tighten the retaining bolts to 31 N.m (23 ft. lbs.).
3. Clean all sealing surfaces of the engine block and the cylinder head(s) (2).
NOTE: Rotate crankshaft 45ยฐ so that all pistons are 1/2 the way down the cylinder bore to avoid piston to valve contact.
4. Position the new cylinder head gasket(s) (1) onto the engine block.
5. Position the cylinder head(s) (2) onto the engine block.
6. Install the cylinder head bolts finger tight.
CAUTION: The 6.4L engine uses a unique 4 layer steel head gasket that must be compressed evenly and completely across the deck surface for proper sealing. The tightening sequence shown in the following illustration must be followed to ensure all layers are compressed before applying the additional 90 degree turn.
7.Using the sequence below, tighten the retaining bolts.
a. Using the sequence shown in illustration, tighten bolts 1-10 to 34 N.m (25 ft. lbs.).
b. Using the sequence shown in illustration, tighten bolts 11-15 to 20 N.m (15 ft. lbs.).
c. Using the sequence shown in illustration, tighten bolts 1-10 to 54 N.m (40 ft. lbs.).
d. Using the sequence shown in illustration, verify bolts 11-15 are 20 N.m (15 ft. lbs.).
e. Using the sequence shown in illustration, tighten bolts 1-10 to 61 N.m (45 ft. lbs.).
f. Using the sequence shown in illustration, rotate bolts 1-10 an additional 90 degrees.
g. Using the sequence shown in illustration, tighten bolts 11-15 to 34 N.m (25 ft. lbs.).
8. Install the pushrods and rocker arms. Refer to ROCKER ARM, VALVE, INSTALLATION.
9. If removed, install the oil dip stick tube and tighten the retaining nut at the exhaust manifold.
10. Position the cylinder head covers, using the sequence shown in illustration, tighten the cylinder head cover bolts to 8 N.m (70 lbs in.). Refer to COVER(S), CYLINDER HEAD, INSTALLATION.
11. Install the power steering pump. Refer to PUMP, INSTALLATION .
12. Rotate the accessory drive belt tensioner (8) clockwise until it contacts it’s stop, install the
accessory drive belt (2), then slowly release the tensioner into position. Refer to BELT, SERPENTINE, INSTALLATION .
13. Raise and support the vehicle.
14. Install the catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
15. Lower the vehicle.
16. Connect the heater hoses (1, 2).
17. Install the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE, INSTALLATION.
18. Connect the fuel supply line.
19. Install the engine covers (1).
20. Fill cooling system. Refer to STANDARD PROCEDURE .
21. Connect the negative battery cable (1).
22. Start engine check for leaks.