Cylinder Head - Installation

INSTALLATION





1. If removed, install the tensioner mounting stud to the cylinder head and tighten to 11 Nm (97 in. lbs.).
2. If removed, install new exhaust maniverter mounting studs Exhaust Manifold Stud Replacement.





3. If removed, install the thermostat housing and gasket with bolts (2) tightened to 10 Nm (89 in. lbs.).






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.

4. Check 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.

5. Clean and prepare the gasket sealing surfaces of the cylinder head and block Engine Gasket Surface Preparation.
6. Install two cylinder head locating dowels (2).
7. Position the new cylinder head gasket (1) on the locating dowels (2).





8. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
9. Install the ten head bolts finger tight.
10. Tighten the cylinder head bolts in the sequence shown, following this 4 step torque plus angle method. Tighten according to the following torque values:
- Step 1: All to 20 Nm (15 ft. lbs.).
- Step 2: All to 30 Nm (22 ft. lbs.).
- Step 3: All + 90° Turn Do not use a torque wrench for this step.
- Step 4: All an additional + 90° Turn Do not use a torque wrench for this step.





11. Connect the heater core inlet hose (1).
12. Connect and lock the engine coolant temperature (ECT) sensor electrical connector (2).





13. Apply engine oil to the oil filter housing coolant return hose O-ring (1).





14. Install the oil filter housing coolant return hose to the thermostat housing (1). Tighten the bolt (4) to 9 Nm (80 in. lbs.).

CAUTION: The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

15. Connect the pressurized coolant bottle return hose (2).
16. Connect the lower radiator hose and tighten the clamp (3).





17. Install the side timing belt cover (1) with bolt (2) tightened to 25 Nm (18 ft. lbs.).





18. Install the maniverter (4), cooling module and front fascia Exhaust Manifold - Installation.





19. Lower the vehicle.
20. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).





21. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 Nm (18 ft. lbs.).
22. Engage the engine wire harness connector (2) to the battery tray (3).
23. Engage two engine wire harness retainers (4) to the battery tray (3).
24. Engage two starter wire harness retainers (6) to the battery tray (3).





25. Connect the powertrain control module (PCM) electrical connectors (1 and 2).





26. Install the camshaft bearing housing Camshaft Bearing Housing - Installation.





27. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair
28. Fill the cooling system Service and Repair.
29. Install the engine cover (1).
30. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
31. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components PCM/ECM Reprogramming .