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 use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
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 20 cylinder head bolts loosely.
2. Tighten the 20 bolts in 3 stages, in the sequence shown.
RH shown, LH similar.
- 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 Cylinder Head Remover/Installer from the LH cylinder head.
4. NOTE: The hydraulic lash adjusters must be installed in their original locations.
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 LH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
6. Position new gaskets, the LH exhaust manifold and tighten 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - LH:
RH cylinder head
7. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
8. NOTE: The hydraulic lash adjusters must be installed in their original locations.
Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
9. Install 8 new RH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
10. Position 2 new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - RH:
11. NOTE: Install 2 new O-ring seals and lubricate the O-ring seals with clean engine coolant.
Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
12. Position the ground strap and install the nut.
- 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 2 front camshaft bearing caps.
- Position the remaining 8 camshaft bearing caps.
- Install the 20 bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: The RH and LH camshaft phaser and sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser and sprocket and the L timing mark to identify the LH camshaft phaser and sprocket.
NOTE: LH shown, RH similar.
Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.
16. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
NOTE: LH shown, RH similar.
Using the Cam Phaser Sprocket Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
17. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body, or permanent compression of the seal bead, will require replacement of the tensioner or engine damage may occur.
Inspect the RH and LH timing chain tensioners.
- Install new tensioners, as necessary.
18. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Compress the tensioner plunger, using a vise.
19. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
20. Remove the tensioner from the vise.
21. 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.
22. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
23. Install the crankshaft sprocket, making sure the flange faces forward.
24. Position the LH and RH timing chain guides and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
25. 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.
26. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the timing chain on the camshaft phaser and sprocket with the camshaft phaser and sprocket timing mark positioned between the 2 copper (marked) chain links.
27. 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).
28. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
29. 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.
30. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
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 camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
31. 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).
32. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
33. NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.
As a post-check, verify correct alignment of all timing marks.
34. Install the crankshaft sensor ring on the crankshaft.
35. NOTICE: 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: Lubricate the roller followers with clean engine oil prior to installation.
Using the Valve Spring Compressor, install all of the camshaft roller followers.
36. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. 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 at the locations shown.
37. Install 3 new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
38. Tighten the 15 engine front cover fasteners in the sequence shown 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).
39. 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.
40. 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. 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.
41. NOTE: If 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. 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.
42. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid may be damaged.
Position the RH valve cover and new gasket on the cylinder head and tighten the 9 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
43. 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. 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.
44. NOTE: If 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. 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. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid may be damaged.
Position the LH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
46. Position the oil level indicator tube and install 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).
47. 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 262 to the bolt threads prior to installation.
- Tighten to 63 Nm (46 lb-ft).
48. Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil.
49. 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.
50. 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.
51. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
52. 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.
53. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
54. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
55. NOTE: LH shown, RH similar.
Install the 8 ignition coils and the 8 bolts.
- 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.
- 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).
56. Position the intake manifold vacuum tube support bracket and install the bolt.
- Tighten to 10 Nm (89 lb-in).
57. Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
58. Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
59. Using a floor crane, remove the engine from the engine stand.
60. NOTICE: Do not use the oil pan to support the engine or oil pan and oil pan gasket damage may occur.
Lower and support the engine assembly on wood blocks.
61. Install the Engine Lifting Bracket.
62. Install the engine. For additional information, refer to Engine Engine - Installation.