Part 1 of 2

Installation

LH cylinder head






1. Position the cylinder head gasket and the cylinder head.

NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.






2. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
- Stage 1: Tighten to 12 Nm (9 lb-ft).
- Stage 2: Tighten to 25 Nm (18 lb-ft).






3. Install the two 8 mm (0.31 in) bolts.






4. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
- Stage 1: Tighten the bolts 90 degrees.
- Stage 2: Tighten the bolts an additional 90 degrees.






5. Install the LH camshaft sprocket in the cassette.

CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.






6. Install the camshaft sprocket bolt.






7. Install the chain guide bolt.
8. Install the LH exhaust manifold.

RH cylinder head






9. Position the cylinder head gasket and the cylinder head.

NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.






10. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
- Stage 1: Tighten to 12 Nm (9 lb-ft).
- Stage 2: Tighten to 25 Nm (18 lb-ft).






11. Tighten the two 8 mm (0.31 in) bolts.






12. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
- Stage 1: Tighten the bolts 90 degrees.
- Stage 2: Tighten the bolts an additional 90 degrees.






13. Install the RH camshaft sprocket in the cassette.

CAUTION: The camshaft sprocket must turn freely. DO NOT tighten the bolt.






14. Install the RH camshaft sprocket bolt.






15. Position the bracket and install the bolt.






16. Position the ground strap and install the bolt.
17. Install the RH exhaust manifold.

Both cylinder heads

CAUTION: The RH sprocket bolt in a left-hand threaded bolt.

NOTE: Use the Camshaft Gear Torque Adapter (303-565) to loosen the camshaft sprocket bolt.






18. If necessary, loosen the RH camshaft sprocket bolt.

NOTE: The camshaft timing slots are off-center.






19. Position the camshaft timing slots below the centerline of the camshaft and install the special tools on the front of the RH cylinder head.






20. If necessary, remove the RH fenderwell splash shield.






21. If necessary, remove the RH camshaft chain tensioner.

NOTE: Leave the top two special tool clamp bolts loose.






22. Install the special tools on the rear of the RH cylinder head.






23. Install the special tool in the RH cylinder head.

CAUTION: The right hand camshaft sprocket bolt is a left-hand thread bolt.






24. Tighten the bolts.
1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft sprocket bolt.






25. Install the RH camshaft chain tensioner.






26. Install the RH fenderwell splash shield.






27. If necessary, remove the LH camshaft chain tensioner.






28. If necessary, loosen the LH camshaft sprocket bolt.

NOTE: Leave the top two special tool clamp bolts loose.






29. Install the special tools on the front of the LH cylinder head.

NOTE: The camshaft timing slots are off center.






30. Position the camshaft timing slots below the centerline of the camshaft and install the special tools on the rear of the LH cylinder head.