Installation

Cylinder Head

Installation

Both sides

1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

Clean and inspect the mating surfaces.
2. Inspect the cylinder head and the cylinder block for flatness.
3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
4. Position the cylinder head gasket on the block.





RH side

5. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs).





6. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs).





7. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.





8. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.

Remove the rubber band. Install the camshaft sprocket and bolt.





9. Install the RH side cassette bolt.
^ Tighten to 10 Nm (89 inch lbs).





10. Position the bracket and install the bolt.
^ Tighten to 28 Nm (21 ft. lbs).





11. Install the RH exhaust manifold.
12. Install the RH fenderwell splash shield.





13. Attach the new wiring harness anchors.





14. Connect the CKP sensor electrical connector.





15. Position the generator mounting bracket and install the bolts.
^ Tighten to 42 Nm (31 ft. lbs).





16. Position the accessory drive belt tensioner and install the bolt.
^ Tighten to 47 Nm (35 ft. lbs).





17. Connect the pushpin and the generator electrical connectors and install the nut.
^ Tighten to 8 Nm (71 inch lbs).





LH side

18. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.

NOTE:New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs).





19. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs).





20. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.





21. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.

Remove the rubber band. Install the camshaft sprocket and bolt.





22. Install the LH side cassette bolt.
^ Tighten to 12 Nm (9 ft. lbs).





23. Position the ground strap and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs).





24. Install the LH exhaust manifold.

25. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires to the LH spark plugs.
26. Install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs).





27. Attach the wiring harness to the LH cylinder head and install the bolt.
^ Tighten to 10 Nm (89 inch lbs).





28. Position the accessory bracket and install the bolts.
^ Tighten to 42 Nm (31 ft. lbs).





29. Position the wiring harness bracket and install the bolt.
^ Tighten to 20 Nm (15 ft. lbs).





Both sides
30. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.





NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed.

NOTE: The following 3 steps are necessary only if the RH cylinder head was not removed.

31. If necessary, install the special tools to the RH cylinder head and tighten the top clamp bolts to 10 Nm (89 inch lbs).





32. CAUTION: The RH camshaft sprocket is a LH-threaded bolt.

If necessary, using the special tool with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt.





33. If necessary, loosen the top 2 special tool clamp bolts.





34. NOTE: Leave the top 2 special tool clamp bolts loose.

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





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

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





36. Install the special tool.





37. CAUTION: The RH camshaft sprocket bolt is a LH-threaded bolt.

Tighten the bolts.
1 Tighten the special tool top clamp bolts to 10 Nm (89 inch lbs).
2 Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt.
^ Tighten to 61 Nm (45 ft. lbs).





38. Install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs).





39. Install the RH fenderwell splash shield.





NOTE: The following 3 steps are necessary only if the LH cylinder head was not removed.

40. If necessary, install the special tools on the LH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 inch lbs).





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





42. If necessary, loosen the top 2 clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.





43. NOTE: Leave the top 2 special tool clamp bolts loose.

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





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

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





45. Install the special tool.





46. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs).
2 Tighten the camshaft bolt.
^ Tighten to 85 Nm (63 ft. lbs).





47. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs).





48. Position the A/C hose bracket and install the nut.
^ Tighten to 20 Nm (15 ft. lbs).





49. NOTE: Inspect the thermostat housing O-ring seal. Install a new O-ring seal if necessary.

Position the thermostat housing, making sure the bypass hose is connected to the water pump, and install the bolts.
^ Tighten to 11 Nm (8 ft. lbs).





50. Position the bypass hose clamp.





51. Connect the ECT sensor electrical connector.





52. Position the fuel rail and install the bolts.
^ Tighten to 23 Nm (17 ft. lbs).





53. Connect the spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
54. Install the roller followers.
55. Install the cooling fan shroud.
56. Install the intake manifold.
57. Fill and bleed the engine cooling system.