Cylinder Head - Installation

INSTALLATION

RIGHT CYLINDER HEAD

CAUTION: 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.

1. Check the cylinder head bolts for necking by holding a scale or straight edge against the threads. 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.

2. Clean the sealing surfaces of the cylinder head and blockEngine Gasket Surface Preparation.
3. Install the camshaft (5) in the cylinder head.

CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT.

CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.

4. Push the camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install the head gasket and cylinder head over the locating dowels.

NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

5. Install and finger tighten eight head bolts (2).

6. Tighten the cylinder head bolts in the sequence shown, using the 4 step torque-turn method to the following torque values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.

7. Bolt torque after the 90° turn (Step 4) should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.

8. Install three inner timing cover to cylinder head bolts (1). Tighten the bolts to 54 Nm (40 ft. lbs.).

CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

9. Push the camshaft back into the cylinder head and install the camshaft sprocket (2).
10. Install a NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft. Counterhold the camshaft sprocket (2) and tighten the camshaft sprocket bolt to 102 Nm (75 ft. lbs.) plus a 90° turn.

11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 Nm (250 in. lbs.).

12. Install a new gasket between the EGR solenoid/valve (3) and the rear of the cylinder head.
13. Position the EGR solenoid/valve assembly to the rear of the cylinder head. Install and tighten two mounting bolts (2) to 8 Nm (80 in. lbs.).

TIMING GEAR ALIGNMENT

14. Rotate the right camshaft gear (2) to align its timing mark (1). Verify that the left camshaft gear (7) timing mark (8) and crankshaft gear (10) timing mark (9) are still aligned.
15. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
16. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten two bolts to 28 Nm (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
17. When the tensioner is in place, pull the retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
18. Rotate the crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.

NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.

19. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for the left head and toward the rear of the engine for the right head.

20. Tighten the ten rocker arm/shaft assembly bolts in the sequence shown to 31 Nm (275 in. lbs.).

21. Clean the cylinder head and cover mating surfaces. Inspect and replace the gasket (1) and seals (2) as necessary Cylinder Head Cover(s) - Installation.
22. Install the cylinder head cover and eight bolts. Tighten bolts to 12 Nm (105 in. lbs.).

23. Install the spark plugs. Tighten to 28 Nm (20 ft. lbs.) Spark Plug - Installation.
24. Install the ignition coils (2) into the cylinder head.
25. Install and tighten the coil mounting bolts to 8 Nm (71 in. lbs.).
26. Reposition the engine wire harness and install the wire harness track retaining tabs (4). Connect and lock electrical connectors to the ignition coils (2), capacitor (3) and EGR valve.

27. Install the front timing belt outer covers (1) with 14 bolts.
28. Tighten the timing cover bolts as follows:
- M6 bolts - 12 Nm (105 in. lbs.)
- M8 bolts - 28 Nm (250 in. lbs.)
- M10 bolts - 54 Nm (40 ft. lbs.)

29. Install the crankshaft damper using Forcing Screw C-4685-C1 (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).

30. Install the crankshaft damper bolt (3). Tighten the bolt to 95 Nm (70 ft. lbs.) while holding the damper (1) with Damper Holding Fixture 9365 (2).

31. Align the power steering pump (3) to the mounting holes on the engine bracket (2) and install three pump mounting bolts (1) through the access holes in the pulley. Tighten the bolts to 28 Nm (21 ft. lbs.).

32. Install the accessory drive belt tensioner (1). Tighten the bolt to 34 Nm (40 ft. lbs.).
33. Install the accessory drive belt idler pulley. Tighten the bolt to 28 Nm (250 in. lbs.).
34. Install the accessory drive belt (6) Serpentine Accessory Drive Belt - Installation.

35. Install the radiator cooling fan assembly (1) into the vehicle.
36. Install the cooling fan mounting bolts and tighten to 6 Nm (50 in. lbs.).
37. Connect the cooling fan electrical connector (2).
38. Install the upper radiator hose (3).

39. Raise and support the vehicle Service and Repair.
40. Install the front exhaust pipe (1). Tighten the ball flange nuts to 34 Nm (25 ft. lbs.).
41. Connect both upstream and downstream (2) oxygen sensor harness connectors.

42. Lower the vehicle.
43. Install the fuel rail (1) and lower intake manifold Intake Manifold - Installation.

44. Install the upper intake manifold (1) including the wiper module, strut tower support and EGR tube Intake Manifold - Installation.

45. Install the air cleaner element housing Air Cleaner Body - Installation
46. Connect the negative battery cable. Tighten nut to 5 Nm (45 in. lbs.).
47. Fill and level check the coolant system Service and Repair.

LEFT CYLINDER HEAD

8. Install four inner timing cover to cylinder head bolts (1) and (2). Tighten the bolts to 54 Nm (40 ft. lbs.).

11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 Nm (250 in. lbs.).

TIMING GEAR ALIGNMENT

12. Rotate the left camshaft gear (7) to align its timing mark (8). Verify that the right camshaft gear (2) timing mark (1) and crankshaft gear (10) timing mark (9) are still aligned.
13. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
14. Holding the tensioner pulley (11) against the belt, install the tensioner into the housing and tighten two bolts to 28 Nm (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
15. When the tensioner is in place, pull the retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
16. Rotate the crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.

NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.

17. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for the left head and toward the rear of the engine for the right head.

18. Tighten the ten rocker arm/shaft assembly bolts in the sequence shown to 31 Nm (275 in. lbs.).

19. Clean the cylinder head and cover mating surfaces. Inspect and replace the gasket (1) and seals (2) as necessary Cylinder Head Cover(s) - Installation.
20. Install the cylinder head cover and eight bolts. Tighten the bolts to 12 Nm (105 in. lbs.).

21. Install the spark plugs. Tighten to 28 Nm (20 ft. lbs.) Spark Plug - Installation.
22. Install the ignition coils (2) into the cylinder head.
23. Install and tighten the coil mounting bolts to 8 Nm (71 in. lbs.).
24. Connect and lock electrical connectors to the ignition coils (2) and install the left cylinder head cover to cylinder head ground strap (3).

25. Install the front timing belt outer covers (1) with 14 bolts.
26. Tighten the timing cover bolts as follows:
- M6 bolts - 12 Nm (105 in. lbs.)
- M8 bolts - 28 Nm (250 in. lbs.)
- M10 bolts - 54 Nm (40 ft. lbs.)

27. Install the crankshaft damper using Forcing Screw C-4685-C1 (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).

28. Install the crankshaft damper bolt (3). Tighten the bolt to 95 Nm (70 ft. lbs.) while holding the damper (1) with Damper Holding Fixture 9365 (2).

29. Align the power steering pump (3) to the mounting holes on the engine bracket (2) and install three pump mounting bolts (1) through the access holes in the pulley. Tighten the bolts to 28 Nm (21 ft. lbs.).

30. Install the accessory drive belt tensioner (1). Tighten the bolt to 34 Nm (40 ft. lbs.).
31. Install the accessory drive belt idler pulley. Tighten the bolt to 28 Nm (250 in. lbs.).
32. Install the accessory drive belt (6) Serpentine Accessory Drive Belt - Installation.

33. Install the radiator cooling fan assembly (1) into the vehicle.
34. Install the cooling fan mounting bolts and tighten to 6 Nm (50 in. lbs.).
35. Connect the cooling fan electrical connector (2).
36. Install the upper radiator hose (3).

37. Raise and support the vehicle Service and Repair.
38. Install the front exhaust pipe (2). Tighten the ball flange nuts to 34 Nm (25 ft. lbs.).
39. Connect both upstream and downstream (3) oxygen sensor harness connectors (1).

40. Lower the vehicle.
41. Install the fuel rail (1) and lower intake manifold Intake Manifold - Installation.

42. Install the upper intake manifold (1) including the wiper module, strut tower support and EGR tube Intake Manifold - Installation.

43. Install the air cleaner element housing Air Cleaner Body - Installation
44. Connect the negative battery cable. Tighten nut to 5 Nm (45 in. lbs.).
45. Fill and level check the coolant system Service and Repair.