Steps 1-35
Cylinder Heads
Special Tool(s)
Material
Installation
Both cylinder heads
1. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal properly. Do not scratch the gasket.
NOTE: LH shown, RH similar.
Install the head gaskets over the dowel pins.
2. CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.
Loosely install cylinder head bolts.
LH cylinder head
3. Tighten the cylinder head bolts in three stages in the sequence shown.
^ Stage 1: Tighten the bolts to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten the bolts an additional 90 degrees.
^ Stage 3: Tighten the bolts an additional 90 degrees.
RH cylinder head
4. Tighten the cylinder head bolts in three stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.
Both cylinder heads
5. Remove the special tool from both ends of the cylinder head.
6. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters in their original locations.
RH cylinder head
7. Using a new gasket, install the RH exhaust manifold. Tighten the nuts in the sequence shown.
LH cylinder head
8. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube.
^ Install a new O-ring seal on the oil level indicator tube.
^ Install the oil level indicator tube.
^ Install the bolt.
9. Using a new gasket, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
Both cylinder heads
10. CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.
CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body, or permanent compression of the seal bead is observed, install a new tensioner.
Compress the tensioner plunger, using an edge of a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides.
15. Pre-position the camshafts.
1 Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
2 Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
16. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Position the crankshaft so the number one cylinder is at TDC with the special tool.
17. Remove the crankshaft holding tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the lower end of the LH timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
20. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
21. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the lower end of the RH timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
24. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post-check, verify correct alignment of all timing marks.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. NOTE: Lubricate the camshaft roller followers, using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Install the camshaft roller followers.
1 Install the special tool.
2 Compress the valve spring.
3 Install the camshaft roller followers in their original locations.
30. Remove the special tool.
31. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
Install the 10 spark plugs.
^ Tighten the spark plugs to 18 Nm (13 ft. lbs.).
32. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
33. Position the balance shaft on the journals.
34. NOTE: It may be necessary to use an inspection mirror to see the marks. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
35. Install the bearing caps in their original locations. Install the bolts and tighten the bolts in the sequence shown.