Cylinder Head - Installation
INSTALLATION - CYLINDER HEAD(S)
RIGHT CYLINDER HEAD
CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT.
The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced..
Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced.
CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper Engine Gasket Surface Preparation.
1. Clean sealing surfaces of cylinder head and block.
CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.
NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.
2. Install the cylinder head over locating dowels and finger tighten the head bolts.
3. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.
4. Bolt torque after 90° turn should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.
5. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 Nm (40 lbs.ft.).
6. Install camshaft sprocket (2) Counterhold the camshaft sprocket gear (2) and tighten the camshaft sprocket bolt to 102 Nm plus a 1/4 turn (75 lbs. ft. plus a 1/4 turn).Timing Belt & Sprockets - Installation.
7. Install the rear camshaft thrust plate (1) and seal (3) and the EGR valve.
8. Rotate the camshaft gear to it's alignment mark (1) and check the left camshaft gear (7) and crankshaft gear timing alignment marks (9).
9. Install the timing belt (4) and tensioner (12)Timing Belt & Sprockets - Installation.
10. Install the timing belt outer cover (1) . Service and Repair
11. Install the accessory drive bracket (2).
12. Install the vibration damper . Service and Repair
13. Install the accessory drive belt tensioner.
14. Install the accessory drive belt idler pulley.
15. Install the accessory drive belt (7).
16. Install the power steering pump (2).
17. Install the right rocker arm assembly.
18. Install the right cylinder head cover, ground strap and insulator.
19. Install lower intake manifold . Service and Repair
20. Install the fuel rail.
21. Install the upper intake manifold . Service and Repair
22. Install the right exhaust manifold . Removal and Replacement
23. Install the exhaust pipe (1) and connect the oxygen sensors.
24. Connect the air cleaner element housing . Service and Repair
25. Fill the coolant system.
26. Connect the negative battery cable.
LEFT CYLINDER HEAD
CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT.
The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.
Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced.
CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper Engine Gasket Surface Preparation.
1. Clean sealing surfaces of cylinder head and block.
CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.
2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine.
NOTE: Before installing the cylinder head bolts, lubricate the threads with engine oil.
3. Install the cylinder head over locating dowels, insert and finger tighten the head bolts.
4. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque-turn method, tighten according to the following torque values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.
5. Bolt torque after 90° turn should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.
6. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 Nm (40 lbs.ft.).
7. Install camshaft sprocket. Counterhold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 102 Nm plus a 1/4 turn (75 lbs. ft. plus a 1/4 turn)
8. Install the rear camshaft thrust plate (1) and seal (3).
9. Rotate the camshaft gear (7) to it's alignment mark (8) and check the right camshaft gear (1) and crankshaft gear timing (9) alignment marks.
10. Install the timing belt (4) and tensioner (11) Timing Belt & Sprockets - Installation.
11. Install the timing belt front cover (1)Timing Cover - Installation.
12. Install the accessory drive bracket (2).
13. Install the accessory drive belt tensioner (5).
14. Install the accessory drive belt idler pulley.
15. Install the accessory drive belt (7).
16. Install the vibration damper (4) . Service and Repair
17. Install the left exhaust manifold. . Removal and Replacement
18. Connect the exhaust pipe (1) and connect the oxygen sensor.
19. Install the left rocker arm assembly.
20. Install the left cylinder head cover and ground strap.
21. Install the power steering pump (2).
22. Install lower intake manifold . Service and Repair
23. Install the fuel rail.
24. Install the upper intake manifold . Service and Repair
25. Connect the air cleaner element housing . Service and Repair
26. Fill the coolant system.
27. Connect the negative battery cable.