Cylinder Head Assembly

CAUTION: Lifter bores are machined surfaces and must not be damaged when installing valve guides, valves, seals, caps, retainers and lifters.





1. Clean all parts:
a. Coat the seven oil gallery plugs with Saturn P/N 21485277 (Loctite 242 Threadlocker or equivalent) and install them using a standard driver, if removed.
b. Coat water jacket plug with Teflon Sealant P/N 21485278, if re-used. Install water jacket plug with a new gasket. Torque to 75 Nm (55 ft. lbs.).

CAUTION: Do not depress the spring cap too far as it will cause valve stem seal and valve stem damage. After each valve is installed, oil the valve guide with clean engine oil and stem before installing the valve stem seal. If a valve stem seal is removed, it must be discarded.

c. Oil the valve stems and install the valves, springs, caps, and retainers.
d. Install new valve stem seals using service tool SA9102E. Do not oil the seal's inner diameter where it contacts the guide.

CAUTION: Do not attempt to use a standard valve spring compressor tool as it can cause damage to the cylinder head hydraulic lifter bore surfaces and valve stems.





e. Use service tool SA9124E to install valve spring retainers.
2. Lubricate the hydraulic lifters with clean engine oil and install them in their proper locations:

CAUTION: Dowel pin in each camshaft must be located at the 12 o'clock position during installation to prevent valve and piston damage.





a. Oil the camshafts (lobes and journals) and install each in the cylinder head with the dowel pin at the 12 o'clock position.

CAUTION: Camshafts are identified IN (intake manifold side of engine) and EX (exhaust side of engine). The camshafts may break if improperly installed. Fully tightening down one bearing cap at a time will break the camshaft and damage the cylinder head cam bearings surfaces or damage the cap bolt threads.

b. The forward bearing caps are used to control thrust; the camshafts must be positioned fully forward prior to their installation.





c. Install all the bearing caps, except the forward one, on each camshaft with arrows pointed toward the camshaft sprockets. The camshaft bearing caps are numbered and have an I for intake side and an E for exhaust manifold side stamped on them. Tighten the caps down uniformly. Torque to 14 Nm (124 inch lbs.).

NOTE: The upper timing chain guide can be installed before timing chain installation. Make sure all gasket surfaces are clean when installing manifolds and cylinder head assembly.








3. Install intake manifold using a new intake manifold casket. Tighten nuts in the following sequence. Torque to 31 Nm (23 ft. lbs.).





4. Install exhaust manifold using a new exhaust manifold gasket. Install gasket with smooth side toward exhaust manifold. Tighten nuts in the following sequence. Torque to 25 Nm (19 ft. lbs.).