Installation

Installation

LH cylinder head





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






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

Install the 12 mm (0.47 inch) bolts and tighten in the sequence shown.





3. Tighten the eight 12 mm (0.47 inch) bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts 80 degrees.
^ Stage 2: Tighten the bolts an additional 80 degrees.





4. Install the two 8 mm (0.31 inch) bolts.





5. Position the LH camshaft sprocket in the chain and install it on the camshaft.






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

Install the camshaft sprocket bolt.





7. Install the chain guide bolt.





8. Install the ground strap and the bolt.





9. Install the engine wiring harness pin-type retainer.
10. Install the LH exhaust manifold.

RH cylinder head





11. Position the cylinder head gasket and the cylinder head.






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

Install the 12 mm (0.47 inch) bolts and tighten in the sequence shown.





13. Tighten the eight 12 mm (0.47 inch) bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts 80 degrees.
^ Stage 2: Tighten the bolts an additional 80 decrees.





14. Install the two 8 mm (0.31 inch) bolts.





15. Position the RH camshaft sprocket in the chain and install it on the camshaft.






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

Install the RH camshaft sprocket bolt.





17. Install the chain guide bolt.





18. Install the bracket and the bolt.
19. Install the LH exhaust manifold.

Both cylinder heads






20. NOTE: The camshaft timing slots are off-center.

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





21. Remove the RH fenderwell splash shield.





22. Remove the RH camshaft tensioner.






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

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





24. Install the special tool.






25. CAUTION: The righthand camshaft sprocket bolt is a lefthand threaded bolt.

NOTE: If necessary, use camshaft gear torque adapter to tighten the camshaft sprocket bolt.

Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.





26. Install the RH camshaft tensioner.





27. Install the RH fenderwell splash shield.





28. Remove the LH camshaft tensioner.






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

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






30. NOTE: The camshaft timing slots are off-center.

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





31. Install the special tool.





32. Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.





33. Install the LH camshaft tensioner.






34. NOTE: Install each roller follower in its original position.

Using the special tool, install the camshaft roller followers.





35. Install the fuel injection supply manifold.
1 Install the fuel injection supply manifold and the fuel injectors as an assembly.
2 Install the fuel supply tube to the fuel manifold.





36. Connect the fuel pressure sensor electrical
37. Connect the LH spark plug wires to the spark plugs.





38. Install the oil level indicator tube and the bolt.





39. Connect the wiring harness casing to the LH cylinder head.





40. Install the accessory bracket and the bolts.





41. Position the wiring harness clip and install the bolt.





42. Install the thermostat housing and the bolts with the coolant bypass hose.





43. Connect the coolant bypass hose clamp.





44. Connect the water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.





45. Secure the new wiring anchors.





46. Connect the Crankshaft Position (CKP) sensor electrical connector.





47. Install the generator mounting bracket and generator as an assembly.
1 Position the generator bracket and install the bolts.
2 Position the drive belt tensioner and install the bolt.





48. Connect the generator electrical connections.
49. Install the RH valve cover.
50. Install the LH valve cover.
51. Install the accessory drive belt.
52. Install the cooling fan shroud.
53. Install the intake manifold.
54. Fill and bleed the cooling system.