Cylinder Head Installation
Installation ProcedureNotice: Set crankshaft to 60° before top-dead center or after TDC to prevent valve to piston contact.
1. Transfer all components. (intake manifold, plugs, ect.)
2. Set crankshaft to 60° before top dead center.
3. Install the cylinder head gasket placing OPEN facing up.
Important: Always use new cylinder head bolts.
4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
5. Lightly apply clean engine oil to threads and to the bottom side of flange of head bolts. Allow oil to drain before installing.
6. Install and torque cylinder head bolts in sequence.
^ Tighten the cylinder head bolts to 30 Nm (22 ft. lbs.) + 155°.
7. Coat the front cylinder head crankcase bolts with Perorated Threadlocker Blue P/N 21485278, or equivalent.
^ Tighten the cylinder head front chain case bolts to 35 Nm (24 ft. lbs.).
8. Install the SA9105E that was removed earlier.
9. Position the exhaust camshaft with offset slot to the 2 o'clock position.
10. Position the intake camshaft with offset slot to the 11 o'clock position.
11. Install timing chain drive sprocket to the crankshaft.
12. Using dampener, rotate the crank so that the mark on the timing chain drive sprocket is at the 5 o'clock position.
13. Install timing chain oiling nozzle and bolt.
^ Tighten the timing chain oil nozzle bolt to 10 Nm (89 ft. lbs.).
14. Assemble the chain to the intake camshaft sprocket aligning the copper link to INT diamond timing mark on camshaft sprocket.
Important: When lowering the timing chain into the cylinder head, rotate the assembly 90° to allow the chain to fall between the cylinder block bosses, then rotate assembly back to that the camshaft sprocket is facing forward.
15. Lower assembly through chain housing opening on top of the cylinder head. Use care to make sure that the chain goes around both sides of the cylinder block bosses.
Important: The crankshaft sprocket timing mark will be at approximately the 5 o'clock position.
16. Route chain around crankshaft sprocket and align silver link to timing mark.
Notice: The camshaft sprocket bolts are not reusable it is a Torque-To-Yield (TTY) bolt, and must be discarded to prevent premature failure.
17. Install the intake camshaft sprocket with the chain in the proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
Important: With the timing chain aligned to crankshaft sprocket mark, the crankshaft can be rotated slightly to eliminate slack from the fixed side of the timing chain. Be sure that the marks are properly aligned.
18. Install new intake camshaft sprocket bolt and finger tighten.
Important: Make sure the crankshaft marks and the camshaft marks aligns with the colored links.
19. Install adjustable timing chain guide through the opening at the top of the cylinder head and install chain guide bolt.
^ Tighten the timing chain guide adjustable bolt to 10 Nm (89 inch lbs.).
20. Install exhaust camshaft sprocket loosely on exhaust camshaft with timing mark on sprocket aligned with silver link.
21. Install new camshaft sprocket bolt loosely.
22. Align the exhaust camshaft sprocket with the chain in proper position to the camshaft. Rotate exhaust clockwise using a 24 mm wrench on flats on camshaft until the camshaft aligns with sprocket.
23. Verify that all colored links are aligned with the appropriate intake (1), crankshaft sprocket (2), and exhaust marks.
24. Verify crankshaft sprocket timing mark is at the 5 o'clock position.
25. If marks are not correct you must repeat the timing procedure.
26. Install the fixed timing chain guide and bolts.
^ Tighten the timing chain fixed bolts to 10 Nm (89 inch lbs.).
27. Apply thread sealant Permatex~ Thread Pipe Sealant (or equivalent) compound to the thread. Install the fixed guide bolt access hole plug.
^ Tighten the timing chain guide bolt access hole plug to 40 Nm (30 ft. lbs.).
Notice: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage the timing chain.
28. Tighten the intake and exhaust camshaft sprocket bolts while holding the camshaft with 24 mm wrench.
^ Tighten the camshaft sprocket bolts to 85 Nm (63 ft. lbs.) +30°.
29. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring or washer is damaged replace the timing chain tensioner.
Important: A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) (1) from end to end. A tensioner in the active state will measure 85 mm (3.35 inch) (1) from end to end.
30. Measure the timing chain tensioner assembly from end to end.
31. If the timing chain tensioner is not in the compressed state, perform the following steps:
31.1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
31.2. Install J45027 (2) into a vise.
31.3. Install notch end of piston assembly into J 45027 (2).
31.4. Using J45027 (1), turn the ratchet cylinder into the piston.
32. Inspect the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with lint free cloth.
33. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
34. At this point the tensioner should measure approximately 72 mm (2.83 inch) (1) from end to end. If the tensioner does not read 72 mm (2.83 inch) (1) from end to end repeat step 30.
35. Ensure all dirt and debris is removed from the timing chain tensioner threaded hold in the cylinder head.
36. Install new timing chain tensioner assembly and tighten.
^ Tighten the timing chain tensioner assembly bolt to 75 Nm (55 ft. lbs.).
37. The timing chain tensioner is released by compressing it 2 mm (0.079 inch) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
38. Install upper timing chain guide and bolts.
^ Tighten the timing chain guide upper bolts to 10 Nm (89 inch lbs.).
39. Raise the vehicle if necessary.
40. Install new front cover gasket.
41. Install the front cover assembly.
42. Install the front cover assembly bolts.
^ Tighten the front cover-to-block bolts to 25 Nm (18 ft. lbs.).
43. Install the front cover water pump bolts.
^ Tighten the water pump bolts to 25 Nm (18 ft. lbs.).
44. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
45. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
46. Install the crankshaft damper pulley.
47. Install new crankshaft balancer pulley bolt with washer assembly.
48. Install crankshaft pulley holder J 38122-A.
^ Tighten the crankshaft pulley bolt to 100 Nm (74 ft. lbs.) +75°.
49. Install accessory drive belt tensioner.
^ Tighten the drive belt tensioner bolt to 50 Nm (37 ft. lbs.).
50. Route belt around the alternator and the A/C compressor.
51. Install J 39914 onto tensioner and upload spring tension from tensioner while positioning belt.
52. Release tensioner and remove the tool
53. Position manifold down pipe with gasket onto flange studs.
54. Install exhaust manifold pipe to exhaust manifold nuts.
^ Tighten the exhaust manifold nuts to 30 Nm (22 ft. lbs.).
55. Attach electrical harness at bottom intake manifold.
56. Position oil level indicator into oil pan assembly.
57. Install oil level indicator tube bolt. Tighten: Tighten the oil level indicator-to-manifold bolt to 10 Nm (89 inch lbs.).
58. Remove the oil drain plug and drain oil.
^ Tighten the oil drain plug to 25 Nm (18 ft. lbs.).
59. Lower the vehicle.
60. Remove the oil filter and install a new oil filter.
61. Fill the engine with oil.
^ Tighten the oil filter cap to 25 Nm (18 ft. lbs.)
62. Install right-hand engine bracket and bolts.
^ Tighten the engine mount bracket-to-engine bolts to 90 Nm (66 ft. lbs.).
63. Install shims on right hand engine mount studs.
64. Install right-hand engine mount onto body side rail studs.
65. Install right-hand engine mount to body nuts.
^ Tighten the engine mount-to-body nuts to 110 Nm (81 ft. lbs.).
66. Install right-hand engine mount to engine mount bracket bolts.
^ Tighten engine mount-to-engine mount bracket bolts to 55 Nm (41 ft. lbs.).
67. Install the right engine inner splash shield.
68. Install the right wheel and hand-tighten wheel nuts.
69. Tighten wheel nuts.
^ Tighten wheel nuts to 125 Nm (92 ft. lbs.).
70. Remove three bar engine support fixture.
71. Visually inspect the camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
72. Assemble the camshaft cover and gasket using care to make sure that the gasket is located in the retaining groove on the camshaft cover.
73. Install cover on the cylinder head and tighten the bolts.
^ Tighten the camshaft cover bolts to 10 Nm (89 inch lbs.).
74. Position engine harness and install fasteners at cam cover.
75. Connect the throttle body connector.
76. Attach ECM ground and ECM connector.
77. Connect the fuel injector harness.
78. Connect the upper radiator hose.
79. Connect the brake booster hose at booster
80. Connect EVAP purge hose and connector.
81. Connect the oxygen sensors at the exhaust manifold.
82. Reposition the fuel line assembly.
Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
83. Install transfer line at fuel-to-fuel rail
^ Tighten the transfer line fitting-to-fuel rail to 10 Nm (89 inch lbs.).
84. Connect the fuel rail bracket and bolt to the cylinder head.
^ Tighten the fuel line bracket bolt to 10 Nm (89 inch lbs.).
85. Connect the ground strap to the camshaft cover assembly.
^ Tighten the camshaft cover ground strap bolts to 10 Nm (89 inch lbs.).
86. Connect the degas hose and attach to the fuel fail.
87. Connect the coolant pipe bracket bolts to the cylinder head.
^ Tighten the coolant pipe bracket bolt to 10 Nm (89 inch lbs.).
88. Install spark plugs, if removed.
^ Tighten the spark plugs to 20 Nm (15 ft. lbs.).
89. Install the ignition module assembly to cam cover and hand tighten retaining bolts.
^ Tighten the Ignition module-to-camshaft cover bolts to 8 Nm (71 inch lbs.).
90. Install air cleaner assembly and bolt.
^ Tighten air cleaner-to-support bracket bolt to 10 Nm (89 inch lbs.).
91. Install outlet resonator/duct assembly into position.
92. Connect PCV fresh air vent hose assembly.
93. Tighten clamp at throttle body assembly.
94. Position outlet resonator/duct assembly up with support bracket and install push-pin.
95. Tighten the clamp at the air cleaner assembly.
96. Connect Intake Air Temperature (IAT) sensor connector.
97. Install coolant.
98. Connect negative battery cable.
^ Tighten the battery terminal bolt to 17 Nm (13 ft. lbs.).
99. Start the vehicle and inspect for leaks.