Cylinder Head - Installation

INSTALLATION





NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced

Necking can be checked by holding a straight edge against the threads (3). If all the threads do not contact the scale (2), the bolt must be replaced.

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

1. Clean sealing surfaces of cylinder head and blockEngine Gasket Surface Preparation.
2. Install new head gasket over locating dowels.
3. Install cylinder head to block, assuring head is properly positioned over locating dowels.




4. Lubricate bolt threads with clean engine oil and install bolts.
5. Tighten bolts in sequence shown for left head (2) and right head (1), using the following steps and torque values:
- Step 1: Bolts 1-8 to 48 Nm (35 ft. lbs.)
- Step 2: Bolts 1-8 to 75 Nm (55 ft. lbs.)
- Step 3: Bolts 1-8 to 75 Nm (55 ft. lbs.)
- Step 4: Bolts 1-8 to +90° Turn Do not use a torque wrench for this step.
- Step 5: Bolts 9-11 to 28 Nm (250 in. lbs.)

6. For left cylinder head installation:
- Install engine oil dipstick tube.
- Install generator.

7. For right cylinder head Installation:
- Install cylinder head ground strap.
- Install EGR valve (if equipped) EGR Valve - Installation.





8. Install all valvetrain components and camshafts Camshaft - Installation. Tighten camshaft bearing caps in sequence shown to 12 Nm (105 in. lbs.).




9. Install primary timing chain (7), guides (2,5,10) and sprockets (9)Timing Chain & Sprockets - Installation.




10. Install coolant outlet (3) Coolant Outlet Housing - Installation.




11. Install lower intake manifold Intake Manifold - Installation.
12. Install cylinder head covers Cylinder Head Cover - Installation.
13. Connect camshaft position sensor (2) and coolant temperature sensor (1) connectors.
14. Install timing chain cover Timing Cover - Installation.
15. Install crankshaft vibration damper Vibration Damper - Installation.
16. Install upper intake manifold Intake Manifold - Installation.




17. Connect oil pressure sensor (1) connector.




18. Install accessory drive belt (5)Accessory Drive Belt - Installation.
19. Fill cooling system.




20. Connect negative battery (1) cable.
21. Start engine and check for leaks.