Part 1
Cylinder Head
All cylinder heads
1. Position the crankshaft keyway at the 11 o'clock position.
2. 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.
LH cylinder head
3. Tighten the 11 bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten the M12 fasteners to 25 Nm (18 lb-ft).
- Stage 2: Tighten the M12 fasteners to 60 Nm (44 lb-ft).
- Stage 3: Tighten the M12 fasteners an additional 90 degrees.
- Stage 4: Tighten the M12 fasteners an additional 90 degrees.
- Stage 5: Tighten the M8 fastener to 20 Nm (177 lb-in).
- Stage 6: Tighten the M8 fastener an additional 45 degrees.
4. Install 8 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
5. Using new exhaust manifold nuts, position the LH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
6. Position the LH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).
RH cylinder head
7. Tighten the 10 bolts in 4 stages, in the sequence shown.
- Stage 1: Tighten the M12 fasteners to 25 Nm (18 lb-ft).
- Stage 2: Tighten the M12 fasteners to 60 Nm (44 lb-ft).
- Stage 3: Tighten the M12 fasteners an additional 90 degrees.
- Stage 4: Tighten the M12 fasteners an additional 90 degrees.
8. Position the ground strap and install the nut.
- Tighten to 10 Nm (89 lb-in).
9. Install 8 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
10. Using new exhaust manifold nuts, position the LH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
11. Position the RH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).
All cylinder heads
12. Using a small pick, carefully push the tensioner rack pawl retainer away from the rack pawl and compress the tensioner plunger and rack using a vise.
13. Install a small pick into the tensioner to hold the rack pawl and plunger in the seated position for tensioner installation.
14. Remove the tensioner from the vise.
15. If the blue links are not visible, mark 2 links on each end, and use as timing marks.
16. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel and above the chain guide pin.
Position the upper end of the LH (inner) timing chain on the LH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.
17. 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 blue (marked) link on the chain and install the crankshaft sprocket onto the crankshaft and verify the crankshaft keyway is at the 11 o'clock position.
18. Install the LH timing chain tensioner arm.
19. Position the LH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
20. Position the LH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
21. Remove the retaining clip from the LH timing chain tensioner.
22. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) chain link.
23. Position the upper end of the RH (outer) timing chain on the RH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.
24. Position the RH timing chain tensioner arm on the dowel pin and the RH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
25. Position the RH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post-check, verify correct alignment of all timing marks.
28. Lubricate the rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean engine oil prior to installation.
29. Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully opened.
30. Position the LH intake rocker arm shaft assembly and install the bolts finger-tight.
31. Tighten the 10 LH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
32. Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully opened.
33. Position the LH exhaust rocker arm shaft assembly and install the bolts finger-tight.
34. Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
35. Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully closed.
36. Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.
37. Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
38. Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully closed.
39. Position the RH exhaust rocker arm shaft assembly and install the bolts finger-tight.
40. Tighten the 10 RH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
