Installation
Installation
Both sides
1. Position the cylinder head gasket on the block.
RH side
2. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
CAUTION: On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
NOTE: Late build vehicles shown, early build vehicles similar.
NOTE: If a new cylinder head must be installed on an early build engine, a kit that contains the cylinder head without an oil supply tube and with 6 new roller followers must be used.
Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
3. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
4. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
5. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
NOTE: Late build vehicles shown, early build vehicles similar.
Remove the rubber band. Install the camshaft sprocket and bolt.
6. NOTE: Late build vehicles shown, early build vehicles similar.
Install the RH side cassette bolt.
^ Tighten to 10 Nm (89 inch lbs.).
7. Inspect the RH exhaust manifold gasket mating surfaces for flatness.
8. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
9. Position a new gasket, the RH exhaust manifold and the new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).
10. Install the catalytic converter-to-RH exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
11. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.
Connect the spark plug wires to the RH spark plugs.
12. Install the engine ground strap and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
13. Position the engine wiring harness and install the bolt.
^ Tighten to 47 Nm (35 ft. lbs.).
14. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
Install the thermostat housing and the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
15. Position the coolant bypass hose clamp.
16. Install the upper radiator hose.
17. Connect the engine coolant temperature (ECT) sensor electrical connector.
18. Install the heater hose to the thermostat housing.
19. Install the generator mounting bracket assembly and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).
20. Position the accessory drive belt tensioner and install the bolt.
^ Tighten to 47 Nm (35 ft. lbs.).
21. Connect the generator electrical connections and install the pushpin.
^ Tighten to 8 Nm (71 inch lbs.).
22. Position the heater hose tube bracket and install the bolts.
^ Tighten the rear bolt to 23 Nm (17 ft. lbs.).
^ Tighten the front bolt to 34 Nm (25 ft. lbs.).
LH side
23. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
NOTE: Late build vehicles shown, early build vehicles similar.
NOTE: If a new cylinder head must be installed on an early build engine, a kit that contains the cylinder head without an oil supply tube and with 6 new roller followers must be used.
Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
24. NOTE: Late build vehicles shown, early build vehicles similar.
Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
25. NOTE: Late build vehicles shown, early build vehicles similar.
Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.
26. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
Remove the rubber band. Install the camshaft sprocket and bolt.
27. Install the LH side cassette bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
28. Inspect the LH exhaust manifold gasket mating surfaces for flatness.
29. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
30. Position a new gasket, the LH exhaust manifold and install the new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).
31. Install the catalytic converter-to-LH exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
32. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.
Connect the spark plug wires to the LH spark plugs.
33. Install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
34. Install the ignition coil bracket and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
35. Install the accessory bracket and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).
36. Install the ignition coil bracket-to-accessory drive bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).
37. Connect the radio ignition interference capacitor electrical connector.
Both sides
38. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
39. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed.
Turn the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC).
40. Remove the nut and position the wiring harness bracket aside.
41. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
Install the special tool.
NOTE: The following 3 steps are necessary only if the RH cylinder head was not removed.
42. NOTE: Late build vehicles shown, early build vehicles similar.
If necessary, install the special tools to the RH cylinder head and tighten the top clamp bolts to 10 Nm (89 inch lbs.).
43. CAUTION: The RH camshaft sprocket is a LH-threaded bolt.
If necessary, using the special tool with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt.
44. If necessary, loosen the top 2 special tool clamp bolts.
45. NOTE: Leave the top 2 special tool clamp bolts loose.
NOTE: Late build vehicles shown, early build vehicles similar.
Install the special tools on the rear of the RH cylinder head.
46. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the front of the RH cylinder head.
47. Install the special tool.
48. CAUTION: The RH camshaft sprocket bolt is a LH-threaded bolt. Tighten the bolts.
1 Tighten the special tool top clamp bolts to 10 Nm (89 inch lbs.).
2 Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt.
^ Tighten to 61 Nm (45 ft. lbs.).
49. Install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
NOTE: The following 3 steps are necessary only if the LH cylinder head was not removed.
50. If necessary, install the special tools on the LH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 inch lbs.).
51. If necessary, loosen the LH camshaft sprocket bolt.
52. If necessary, loosen the top 2 clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
53. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the front of the LH cylinder head.
54. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
55. Install the special tool.
56. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.
^ Tighten to 85 Nm (63 ft. lbs.).
57. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
58. Position the wiring harness bracket and install the nut.
^ Tighten to 20 Nm (15 ft. lbs.).
59. Install the roller followers.
60. Fill and bleed the engine cooling system.