Installation

Cylinder Heads

Special Tool(s):

Special Tool(s):

Material:

Material:

Installation

Both cylinder heads

1. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.





Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.





LH cylinder head
2. Tighten the cylinder head bolts in 3 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





RH cylinder head
3. Tighten the cylinder head bolts in 3 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





Both cylinder heads

4. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

Install the hydraulic lash adjusters in their original locations.





RH cylinder head
5. Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





LH cylinder head
6. Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





Both cylinder heads

7. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Compress the tensioner plunger, using a vise.





8. Install a retaining clip on the tensioner to hold the plunger in during installation.





9. NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.





10. Install the timing chain guides and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





11. Preposition the camshafts.
1 Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2 Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.





12. Position the crankshaft with the special tool, then remove the tool.





13. Install the crankshaft sprocket, making sure the flange faces forward.





14. Install the lower end of the LH timing chain, aligning the timing marks.





15. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.





16. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





17. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.





18. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.





19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





20. Remove the retaining clips from the RH and LH timing chain tensioners.





21. Check for correct alignment of all timing marks.





22. Install the crankshaft sensor ring on the crankshaft.
23. Lubricate the balance shaft journals with clean engine oil.





24. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.





25. Position the balance shaft on the journals.





26. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.





27. Install the balance shaft bearing caps in their original locations and tighten the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





28. NOTE: Camshaft roller follower is shown removed for clarity.

Install the special tool between the valve spring coils to prevent valve stem seal damage.





29. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

NOTE: Position the cam lobe away from the camshaft roller follower prior to installing each camshaft roller follower.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Use the special tool to compress the valve springs, and install each of the camshaft roller followers.

30. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.

Install the 10 spark plugs.
^ Tighten the spark plugs to 18 Nm (13 ft. lbs.).





31. NOTE: If the front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.





32. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.











33. Tighten the engine front cover fasteners in sequence in 2 stages.
^ Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 ft. lbs.).





34. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.





35. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.





36. NOTE: If the front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
37. Position the valve covers.





38. Tighten the fasteners in the sequence shown.





39. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





40. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





41. Using the special tools, install a new crankshaft front seal.





42. NOTE: If the front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





43. Using the special tool, install the crankshaft pulley.





44. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.

Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 ft. lbs.).





45. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





46. NOTE: The front lower hole in the power steering pump is not used.

Position the power steering pump and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





47. Position the oil level indicator tube.





48. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
^ Tighten to 10 Nm (89 inch lbs.).





49. Install the oil level indicator and tube support bracket nut.
^ Tighten to 25 Nm (18 ft. lbs.).





50. Position the crankcase vent tube and connect the quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





51. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 ft. lbs.).
52. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.





53. Connect the crankshaft position (CKP) sensor electrical connector.





54. Connect the engine oil pressure (EOP) sensor electrical connector.





55. Connect the knock sensor (KS) electrical connector.





56. Connect the RH radio frequency interference capacitor electrical connector.





57. Connect the camshaft position (CMP) sensor electrical connector.





58. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.





59. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
^ Tighten to 24 Nm (18 ft. lbs.).





60. Position the RH engine support insulator and install the 3 bolts.
^ Tighten to 63 Nm (46 ft. lbs.).





61. Install the special tool.





62. Install the special tool.





63. Install the special tool and remove the engine from the work stand.
64. Lower the engine onto wooden blocks.





65. Install the special tool and raise the engine.





66. Position the flexplate and tighten the 8 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (59 ft. lbs.).
67. Install the engine.