Part 1

INSTALLATION

Cylinder Head

Special Tools:

Material:

All cylinder heads

1. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

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.

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

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

4. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

NOTE: The hydraulic lash adjusters must be installed in their original locations.

Install the hydraulic lash adjusters into the LH cylinder head.

5. Remove the oil level indicator tube, install a new O-ring seal, and lubricate the O-ring seal with clean engine oil. Position the oil level indicator tube loosely in the engine block before installing the LH exhaust manifold.
6. Inspect the LH exhaust manifold gasket mating surfaces for flatness.
7. Install 8 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).

8. Position new gaskets, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).

9. Position the LH exhaust manifold heat shield and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).

RH cylinder head
10. Tighten the RH cylinder head bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.

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

12. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

NOTE: The hydraulic lash adjusters must be installed in their original locations.

Install the hydraulic lash adjusters into the RH cylinder head.

13. Inspect the RH exhaust manifold gasket mating surfaces for flatness.
14. Install 8 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).

15. Position new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).

16. Position the RH heat shield and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).

17. NOTE: Install new O-ring seals and lubricate the O-ring seals with clean engine coolant.

Position the heater supply tube and the hoses as an assembly and install the stud bolt.
^ Tighten to 10 Nm (89 inch lbs.).

18. Position the ground strap and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).

All cylinder heads

19. NOTE: Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

Install the LH and RH camshafts.

20. NOTE: LH shown, RH similar.

NOTE: Lubricate the camshaft bearing caps with clean engine oil.

Install the LH and RH camshaft bearing caps in their original locations.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
^ Tighten to 10 Nm (89 inch lbs.) in the sequence shown.

21. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

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.

NOTE: LH shown, RH similar.

Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.

22. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.