Cylinder Head Assembly

Cylinder Head-Bolts

NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced (Fig. 31).





Tighten the cylinder head bolts in the sequence shown in (Fig. 33). Using the 4 step torque-turn method, tighten according to the following values:

- First: All to 34 Nm (25 ft. lbs.)
- Second: All to 82 Nm (60 ft. lbs.)
- Third: All to 82 Nm (60 ft. lbs.)

CAUTION: Do not use a torque wrench for the Fourth step.

- Fourth: Turn all bolts an additional 1/4 Turn





Cylinder Head Cover-Bolts 12 Nm (105 inch lbs.)

Exhaust Manifold

Non-Turbo





Exhaust Manifold-Bolts 23 Nm (200 ft. lbs.)
Starting at center and progressing outward in both directions
Tighten fasteners to 23 Nm (200 ft. lbs.).
Exhaust Manifold Heat Shield-Bolts 12 Nm (105 inch lbs.)

Turbo

Exhaust Manifold

NOTE: The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger.

Intake Manifold

Non-Turbo Upper





Intake Manifold
Upper-Bolts 12 Nm (105 inch lbs.)

Non-Turbo Lower





Intake Manifold
Lower-Bolts 12 Nm (105 inch lbs.)

Turbo Upper





Intake Manifold
Upper-Bolts (Turbo)

NOTE: This engine could be equipped with either a plastic intake manifold or an aluminum intake manifold.

Position upper intake manifold on lower intake manifold.

Aluminum intake manifold
Tighten manifold fasteners to 28 Nm (250 inch lbs.)
Sequence shown in (Fig. 152).
Plastic intake manifold
Tighten manifold fasteners to 12 Nm (105 inch lbs.)
Sequence shown in (Fig. 152).

Turbo Lower





Intake Manifold
Lower-Bolts (Turbo)

Note: Turbocharged Engine: Replace lower intake manifold gasket.

Aluminum manifold
Tighten fasteners to 28 Nm (250 inch lbs.)
Sequence shown in (Fig. 154).
Plastic manifold
Tighten fasteners to 12 Nm (105 inch lbs.)
Sequence shown in (Fig. 154)








Camshaft Bearing Caps
Install right and left No. 2 - 5 and right No. 6.
Tighten M6 fasteners to 12 Nm (105 inch lbs.)
in sequence shown in (Fig. 42).

NOTE: Bearing end caps must be installed before seals can be installed.

Camshaft Sprocket-Bolt 115 Nm (85 ft. lbs.)

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER
Journals No.1 - 6 26.020 - 26.041 mm 1.024 - 1.025 in

CYLINDER HEAD
Gasket Thickness (Compressed) 0.71 mm 0.028 in.

CAMSHAFT
Journal Diameter No. 1-6 25.976 - 25.995 mm 1.022 - 1.023 in.
Bearing Clearance - Diametrical 0.025 - 0.065 mm 0.0009 - 0.0025 in.
End Play 0.05 - 0.17 mm 0.0019 - 0.0066 in.
Lift (Zero Lash)
Intake 8.25 mm (0.324 inch)
Exhaust 6.60 mm (0.259 mm)
Intake Valve Timing*
Closes (ABDC) 44.3°
Opens (ATDC) 6.2°
Duration 218°
Exhaust Valve Timing*
Closes (ATDC) 0.8°
Opens (BBDC) 39.9°
Duration 220.7°
Valve Overlap 5.4°

*All reading in crankshaft degrees at 0.5 mm (0.019 inch) valve lift.