Installation

Cylinder Head














Installation

All cylinder heads

1. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.

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.





2. NOTE: RH shown, LH similar.

Tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





LH cylinder head
3. Remove the special tool from the LH cylinder head.





4. Install the hydraulic lash adjusters into the LH cylinder head.
^ Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.





5. Install 8 new exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





6. Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





7. Position the exhaust manifold heat shield and install the 3 bolts.





RH cylinder head
8. Remove the special tool from the RH cylinder head.





9. Install the hydraulic lash adjusters into the RH cylinder head.
^ Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.





10. Install 8 new exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





11. Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





12. Install the coolant tube and the stud bolt.
^ Tighten to 10 Nm (89 lb-in).





All cylinder heads
13. Install the LH and RH camshafts.
^ Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

14. NOTE: LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.
^ Lubricate the camshaft bearing caps with clean engine oil.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
^ Tighten to 10 Nm (89 lb-in) in the sequence shown.





15. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Install the variable camshaft timing (VCT) phaser sprockets and new VCT phaser sprocket bolts finger tight.





16. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.

NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.





17. 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. Failure to follow these instructions may result in engine damage.

Compress the tensioner plunger, using a vise.





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





19. Remove the tensioner from the vise.
20. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.





21. Position the crankshaft using the special tool, then remove the tool.





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





23. Install the 4 bolts and the LH and RH timing chain guides.
^ Tighten to 10 Nm (89 lb-in).





24. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.





25. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.





26. 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 lb-ft).





27. Remove the retaining clip from the LH timing chain tensioner.





28. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.





29. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.





30. 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 lb-ft).





31. Remove the retaining clip from the RH timing chain tensioner.





32. As a post-check, verify correct alignment of all timing marks.





33. Install the crankshaft sensor ring on the crankshaft.





34. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the special tool, install all of the camshaft roller followers.
^ Lubricate the camshaft roller followers with clean engine oil prior to installation.





35. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

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

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

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.





36. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.





37. Tighten the engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).











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

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
39. Install the 4 front oil pan bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.





40. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 in 2 places where the engine front cover meets the cylinder head.





41. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





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

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

43. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 in 2 places where the engine front cover meets the cylinder head.





44. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





45. Install the oil level indicator tube and the bolt.
^ Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 lb-in).





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





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





48. Using the special tools, install a new crankshaft front seal into the engine front cover.





49. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.





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





51. Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.





52. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





53. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

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





54. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Position the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





55. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).





56. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
^ Tighten to 25 Nm (18 lb-ft).





57. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.

58. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.
^ Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
^ Tighten to 6 Nm (53 lb-in).





59. Install the LH radio ignition interference capacitor and the nut.
^ Tighten to 25 Nm (18 lb-ft).





60. Connect the cylinder head temperature (CHT) sensor electrical connector.





61. Connect the 4 RH ignition coil electrical connectors.





62. Connect the electrical connector retainer to the coolant tube.





63. Connect the 2 engine wiring harness retainers from the RH valve cover studs.





64. NOTE: RH shown, LH similar.

Connect the RH and LH VCT solenoid electrical connectors.





65. Install the RH radio ignition interference capacitor and the stud bolt.
^ Tighten to 25 Nm (18 lb-ft).





66. NOTE: RH shown, LH similar.

Connect the RH and LH CMP sensor electrical connectors.





67. Using a suitable floor crane, remove the engine from the engine stand.
68. Install the flexplate and the 8 bolts in the sequence shown.
^ Tighten to 80 Nm (59 lb-ft).





69. Install the engine.