Part 1 of 2
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.
NOTE: LH shown, RH similar.
Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
2. NOTE: Be sure to tighten the bolts in 3 stages.
Tighten the 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.
LH cylinder head
3. Remove the special tool from the LH cylinder head.
4. Install the hydraulic lash adjusters into the LH cylinder head.
^ Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
5. Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
RH cylinder head
6. Remove the special tool from the RH cylinder head.
7. Install the hydraulic lash adjusters into the RH cylinder head.
^ Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
8. Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
9. Install the coolant tube and the stud bolt.
^ Tighten to 10 Nm (89 inch lbs.).
All cylinder heads
10. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
NOTE: Camshaft shown installed to clarify camshaft roller follower position.
Install only the identified camshaft roller followers onto the RH cylinder head.
11. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
NOTE: Camshaft shown installed to clarify camshaft roller follower position.
Install only the identified camshaft roller followers onto the LH cylinder head.
12. Install the LH and RH camshafts.
^ Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
13. Install the LH and RH camshaft bearing caps in their original locations.
^ Lubricate the camshaft bearing caps with clean engine oil.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
14. Tighten the LH camshaft bearing cap bolts in 2 stages:
^ Stage 1: Tighten to 8 Nm (71 inch lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 45 degrees.
15. Tighten the RH camshaft bearing cap bolts in 2 stages:
^ Stage 1: Tighten to 8 Nm (71 inch lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 45 degrees.
16. Install the balance shaft drive gear onto the LH camshaft.
17. NOTE: RH shown, LH similar.
Install the camshaft sprockets and camshaft sprocket bolts finger tight.
18. 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.
19. Install a retaining clip on the tensioner to hold the plunger in during installation.
20. NOTE: There are 61 links in each timing chain
If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.
21. Install the timing chain guides and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
22. Preposition the camshafts.
1. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
23. Position the crankshaft with the special tool, then remove the tool.
24. Install the crankshaft sprocket, marking sure the flange faces forward.
25. Install the lower end of the LH timing chain, aligning the timing marks.
26. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.
Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
27. 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 and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
28. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.
NOTE: The lower half of the timing chain must be positioned above the dowel.
Install the RH (outer) timing chain on the crankshaft sprocket.
29. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
30. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
31. Remove the retaining clips from the RH and LH timing chain tensioners.
32. Check for correct alignment of all timing marks.
33. Install the crankshaft sensor ring on the crankshaft.
34. Lubricate the balance shaft journals with clean engine oil.
35. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
36. Position the balance shaft on the journals.
37. NOTE: It may be necessary to use an inspection mirror to see the marks.
Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
38. NOTE: Install the balance shaft bearing caps in their original locations
Install the bolts and tighten in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
39. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
Tighten the RH camshaft sprocket bolt in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 90 degrees.
40. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
Tighten the LH camshaft sprocket bolt in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 90 degrees.