Cylinder Head Assembly
Cylinder Head
NOTICE: 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.
NOTICE: 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 future oil leakage.
NOTICE: 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 10 cylinder head bolts loosely.
2. NOTE: RH shown, LH similar.
Tighten the 10 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.
LH cylinder head
3. Remove the Cylinder Head Remover/Installer from the LH cylinder head.
4. Install the 12 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 (106 lb-in).
6. Position a new gasket and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - LH:
7. Position the intake manifold vacuum tube support bracket and install the bolt.
- Tighten to 10 Nm (89 lb-in).
RH cylinder head
8. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
9. Install the 12 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 (106 lb-in).
11. Position a new gasket and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - RH:
12. Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
All cylinder heads
13. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
14. Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
15. 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 20 bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown.
16. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: LH shown, RH similar.
Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.
17. 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 and sprocket.
NOTE: LH shown, RH similar.
Using the Cam Phaser 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.
18. 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.
19. Install the 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. Install the crankshaft sprocket, making sure the flange faces forward.
23. Position the LH and RH timing chain guides and install the 4 bolts.
- 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 camshaft phaser and 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 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
27. Remove the Hydraulic Chain Tensioner 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 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 phaser and sprocket. Make sure the timing mark is 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 the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
31. Remove the Hydraulic Chain Tensioner 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. 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 Valve Spring Compressor, install all of the camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
35. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may 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 15 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. Install the 4 front oil pan bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
39. 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.
40. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
41. NOTICE: 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 9 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
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. 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. 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 may cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
44. NOTICE: 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 10 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
45. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
46. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.
47. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
48. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
49. 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.
50. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
51. Position the oil level indicator and tube and install the bolt.
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
52. Install the oil level indicator and tube front bolt.
- Tighten to 25 Nm (18 lb-ft).
53. 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).
54. Position the electrical harness on the engine assembly.
55. Connect the Engine Oil Pressure (EOP) switch electrical connector.
56. Connect the engine wiring harness position retainers to the front of the RH valve cover.
57. Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP sensor electrical connector.
58. Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
59. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
60. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
61. Connect the RH VCT solenoid electrical connector.
62. Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
63. Connect the RH CMP sensor electrical connector.
64. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
NOTICE: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.
NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.
NOTE: Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
If equipped with cylinder block drain plugs, position the RH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
65. NOTICE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.
NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.
Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
- Tighten to 55 Nm (41 lb-ft).
66. Install the Engine Lifting Bracket.
67. Using a suitable floor crane, remove the engine from the engine stand.
68. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
69. Install the engine. For additional information, refer to Engine Engine - Installation.