Installation

Cylinder Heads








Special Tool(s)





Material

All cylinder heads





1. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and 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 cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
- LH shown, RH similar.

LH cylinder head





2. NOTE: Make sure to tighten the bolts in sequence in 3 stages.

Tighten the LH bolts 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.

RH cylinder head





3. NOTE: Make sure to tighten the bolts in the following 3 stages.

Tighten the RH bolts 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.

All cylinder heads





4. CAUTION: Timing chain procedures must be followed exactly or damage to 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 a vise.





5. Install a retaining clip on the tensioner to hold the plunger in during installation.

6. Remove the tensioner from the vise.





7. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.





8. Install the crankshaft sprocket, making sure the flange faces forward.





9. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the LH bolts.
3. Position the RH timing chain guide.
4. Install and tighten the RH bolts.
- Tighten to 10 Nm (89 inch lbs.).





10. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.





11. NOTE: The number one cylinder 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.

12. Remove the Crankshaft Holding Tool.





13. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





14. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





15. 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.
- Tighten to 25 Nm (18 ft. lbs.).





16. Remove the retaining clip from the LH timing chain tensioner.





17. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





18. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
- Tighten to 25 Nm (18 ft. lbs.).





20. Remove the retaining clip from the RH timing chain tensioner.





21. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.





22. NOTE: Camshaft roller follower is shown removed for clarity.

Install the special tool between the valve spring coils to prevent valve stem seal damage.





23. NOTE: The camshaft roller followers must be reinstalled in their original locations.

NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.

Use the special tool to compress the valve springs, and install the camshaft roller follower.

24. NOTE: The camshaft roller followers must be reinstalled in their original locations.

Repeat the previous 3 steps for each of the camshaft roller followers.





25. Install the crankshaft sensor ring on the crankshaft.





26. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.





27. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.











28. Tighten the engine front cover fasteners in the sequence shown.





29. Install the camshaft position (CMP) sensor and the bolt.
- Lubricate the new O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 inch lbs.).





30. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





31. Use the special tools to install the crankshaft front seal into the engine front cover.





32. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





33. Use the special tool to install the crankshaft pulley.





34. Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 ft. lbs.).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 ft. lbs.).
- Stage 4: Tighten an additional 90 degrees.





35. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
- Tighten to 25 Nm (18 ft. lbs.).





36. Position the accessory drive belt tensioner and install the bolts.
- Tighten to 25 Nm (18 ft. lbs.).

37. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Inspect and clean the valve cover sealing surfaces with metal surface cleaner.





38. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.





39. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.





40. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.





41. Tighten the valve cover bolts in the sequence shown.
- Tighten to 10 Nm (89 inch lbs.).

42. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Inspect and clean the valve cover sealing surfaces with metal surface cleaner.





43. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.





44. NOTE: If not secure within minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.





45. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.





46. Tighten the valve cover bolts in the sequence shown.
- Tighten to 10 Nm (89 inch lbs.).





47. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors.
- Tighten to 25 Nm (18 ft. lbs.).

LH cylinder head





48. 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.
- Tighten to 10 Nm (89 inch lbs.).





49. Install the LH exhaust manifold and the exhaust manifold gasket. Tighten the nuts in the sequence shown.
- Tighten to 25 Nm (18 ft. lbs.).

RH cylinder head





50. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
- Tighten to 25 Nm (18 ft. lbs.).





51. Slide the heater outlet tube forward with a new O-ring seal into the cylinder block.
- Lubricate the O-ring seal with engine coolant.





52. Install the heater outlet tube studs.
- Tighten to 25 Nm (18 ft. lbs.).





53. Connect the coolant hoses to the heater outlet tube.

All cylinder heads.





54. Connect the RH radio ignition interference capacitor electrical connector.





55. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.





56. Position the upper radiator hose bracket and install the nut.
- Tighten to 10 Nm (89 inch lbs.).





57. Connect the CMP sensor electrical connectors.





58. Connect the CKP sensor electrical connector.





59. Install the special tool.

60. Using a suitable floor crane, remove the engine from the engine stand.





61. Install the spacer plate.





62. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 inch lbs.).
- Stage 2: Tighten to 80 Nm (59 ft. lbs.).

63. Install the engine. Engine