Cylinder Head - Installation - RH

Cylinder Head - RH





NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 90 degrees.





2. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).





3. NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

Install the valve tappets.





4. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.





5. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using new gaskets, install the lower intake manifold and the 10 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





6. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





7. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: The upper and lower O-ring seals are not interchangeable.

Install new fuel injector O-ring seals.

- Remove the retaining clips and separate the fuel injectors from the fuel rail.

- Remove and discard the O-ring seals.

- Install new O-ring seals and lubricate with clean engine oil.

- Install the fuel injectors and the retaining clips onto the fuel rail.





8. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





9. Install the coolant bypass hose to the thermostat housing.





10. NOTE: Align the bracket with the index mark made during removal.

Install the upper intake manifold support bracket and the bolt.

- Tighten to 10 Nm (89 lb-in).





11. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





12. Install the RH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





13. Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





14. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





15. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).





16. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





17. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).





18. If equipped, install the block heater wiring harness onto the engine.
- Connect the block heater electrical connector and install the heat shield.





19. Using a new gasket, install the RH catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





20. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.





21. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).





22. Install the 2 LH catalytic converter bracket bolts.
- Tighten to 20 Nm (177 lb-in).





23. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.





24. Connect the CHT sensor electrical connector.





25. Connect the 6 fuel injector electrical connectors (3 shown).





26. Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).





27. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).





28. Install the RH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





29. Connect the RH CMP sensor electrical connector.





30. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.





31. Install the RH camshafts. For additional information, refer to Camshaft Camshaft - Installation.