11. Cylinder Head Assemble

Cylinder Head Assemble

Tools Required
* J 8062 Valve Spring Compressor - Head Off
* KM-653-A Adaptor




1. Install new valve stem seals.
2. Lubricate the valve stems with engine oil.
3. Carefully install the valves in their original positions. Do not damage the valve stem seals.
4. Install the valve springs in their original positions.
5. Install the valve spring caps.




6. Compress the valve springs with J 8062 and KM-653-A.
7. Install the valve keys.
8. Remove J 8062 and KM-653-A.




9. Lubricate the valve tappet adjusters with engine oil.
10. Install the valve tappet adjusters.




11. Install the intake camshaft.
12. Install the intake camshaft caps in their original positions.
13. Install the exhaust camshaft.
14. Install the exhaust camshaft caps in their original positions.
15. Install the camshaft cap bolts.

Notice: Refer to Fastener Notice.

16. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

Tighten the camshaft cap bolts to 16 N.m (12 lb ft).




17. Install the spark plugs.

Tighten the spark plugs to 25 N.m (18 lb ft).

18. Install the exhaust gas recirculation (EGR) valve adapter gasket.
19. Install the EGR valve adapter.
20. Install the EGR valve adapter bolts.

Tighten the exhaust gas recirculation valve adapter bolts to 25 N.m (18 lb ft).

21. Install the direct ignition system (DIS) coil mounting bracket.
22. Install the DIS coil mounting bracket bolts.

Tighten the direct ignition system coil mounting bracket bolts to 10 N.m (89 lb in).

23. Install the DIS coil with the ignition wires attached.
24. Install the DIS coil mounting bolts.

Tighten the direct ignition system coil mounting bolts to 10 N.m (89 lb in).




25. Install the intake manifold studs.
26. Install the intake manifold gasket.
27. Install the intake manifold.
28. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

Tighten the intake manifold retaining nuts and retaining bolts to 25 N.m (18 lb ft).




29. Install the fuel rail assembly with the bolts.

Tighten the fuel rail assembly retaining bolts to 25 N.m (18 lb ft).

30. Install the thermostat housing assembly.
31. Install the thermostat housing mounting bolts.

Tighten the thermostat housing mounting bolts 20 N.m (15 lb ft).




32. Install the exhaust manifold studs.
33. Install the exhaust manifold gasket.
34. Install the exhaust manifold.
35. Install the exhaust manifold retaining nuts in the sequence shown.

Tighten the exhaust manifold retaining nuts to 25 N.m (18 lb ft).

36. Install the exhaust manifold heat shield.
37. Install the exhaust manifold heat shield bolts.

Tighten the exhaust manifold heat shield bolts to 15 N.m (11 lb ft).




38. Install the coolant temperature sensor.

Tighten the coolant temperature sensor to 20 N.m (15 lb ft).

39. Install the cylinder head with the intake manifold and the exhaust manifold attached.