Cylinder Head - Installation
Cylinder Head
All cylinder heads
1. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow this instruction may result in engine damage.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 10 cylinder head bolts loosely.
LH cylinder head
2. Tighten the 10 LH cylinder head 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.
RH cylinder head
3. NOTE: Make sure to tighten the bolts in the following 3 stages.
Tighten the RH bolts 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.
All cylinder heads
4. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTICE: 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 or engine damage may occur.
Compress the tensioner plunger, using a vise.
5. Install a retaining clip on the tensioner to hold the plunger in during installation.
6. Remove the tensioner from the vise.
7. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
8. Install the crankshaft sprocket, making sure the flange faces forward.
9. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the 2 LH bolts.
3. Position the RH timing chain guide.
4. Install and tighten the 2 RH bolts.
- Tighten to 10 Nm (89 lb-in).
10. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
11. NOTE: The No. 1 cylinder is at Top Dead Center (TDC) when the stud on the engine block fits into the slot in the handle of the Crankshaft Holding Tool.
Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.
12. Remove the Crankshaft Holding Tool.
13. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
14. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
15. 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 the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
16. Remove the retaining clip from the LH timing chain tensioner.
17. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
18. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
20. Remove the retaining clip from the RH timing chain tensioner.
21. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
22. Install the crankshaft sensor ring on the crankshaft.
23. NOTICE: 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. 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: 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.
24. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
25. Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
26. Loosely install the 4 bolts, then tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
27. NOTE: RH shown, LH similar.
Position the 2 radio interference capacitors and install the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
28. Install the Camshaft Position (CMP) sensor and the bolt.
- Lubricate the O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
29. Install the Crankshaft Position (CKP) sensor and the bolt.
- Lubricate the O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
30. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
31. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.
32. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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 in the crankshaft pulley.
33. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
34. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the 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.
35. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
36. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
37. NOTE: Camshaft roller follower is removed from art for clarity.
Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
38. NOTICE: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Engine Engine - Removal.
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Position the cam lobe away from the camshaft roller follower prior to installing each camshaft roller follower.
Using the Valve Spring Compressor, compress the valve springs and install the camshaft roller followers.
39. Repeat the previous 2 steps for each of the roller followers.
40. NOTICE: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Install the 8 spark plugs.
41. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors.
- Tighten to 25 Nm (18 lb-ft).
42. NOTICE: 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.
Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
43. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
44. 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.
45. Position the RH valve cover and gasket on the cylinder head and install the 11 bolts loosely.
46. Position the RH valve cover and gasket and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).
47. NOTICE: 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.
Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
48. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
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 in 2 places where the engine front cover meets the cylinder head.
50. Position the LH valve cover and gasket and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).
LH cylinder head
51. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube.
- Install a new O-ring seal on the oil level indicator tube.
- Install the oil level indicator tube.
- Install the bolt.
- Tighten to 10 Nm (89 lb-in).
52. Install 8 new LH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
53. Install the LH exhaust manifold and new exhaust manifold gasket. Tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
54. Install the LH cylinder head insert.
RH cylinder head
55. Install 8 new RH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
56. Install the new RH exhaust manifold gaskets and the exhaust manifold. Tighten the new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
57. Position the exhaust manifold heat shield and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
58. Install heater outlet tube stud, the ground strap and the nut.
- Tighten the heater outlet tube stud to 25 Nm (18 lb-ft).
- Tighten the nut to 10 Nm (89 lb-in).
59. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
All cylinder heads
60. NOTE: LH shown, RH similar.
If equipped, install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
61. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
If equipped with cylinder block drain plugs, position the RH engine support insulator and install the 3 bolts.
- Apply threadlock to the bolt threads prior to installation.
- Tighten to 63 Nm (46 lb-ft).
62. NOTICE: Do not sideload the cooling fan clutch coil or the cooling fan clutch coil may be damaged.
Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the cooling fan.
- Calculate the correct torque wrench setting for the following torque.
- Tighten to 55 Nm (41 lb-ft).
63. Position the cooling fan clutch wiring harness and install the nut.
- To install, tighten to 10 Nm (89 lb-in).
64. Install the Engine Lifting Bracket.
65. Using a suitable floor crane, remove the engine from the engine stand.
66. Install the spacer plate.
67. Position the flexplate and install the 6 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
68. Install the engine. For additional information, refer to Engine Engine - Installation.