Part 2

Cylinder Head

















41. NOTICE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Tighten the LH camshaft sprocket bolt in 2 stages:

- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





42. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.





43. Remove the 2 bolts and the middle balance shaft bearing support and camshaft bearing cap assembly.





44. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push down on the valve while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.

- Lubricate the camshaft roller follower with clean engine oil prior to installation.





45. Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.





46. Remove the 2 bolts and the rear balance shaft bearing support and camshaft bearing cap assembly.





47. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push down on the valve while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.

- Lubricate the camshaft roller follower with clean engine oil prior to installation.





48. Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.





49. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push down on the valve while compressing the spring.

Using the Valve Spring Compressor, install all of the remaining camshaft roller followers.

- Lubricate the camshaft roller followers with clean engine oil prior to installation.





50. Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.

51. Lubricate the balance shaft journals with clean engine oil.

52. NOTE: Camshaft sprocket removed from art for clarity.

Position the balance shaft on the journals and align the timing mark on the balance shaft with the camshaft timing mark as shown.





53. NOTICE: The balance shaft bearing caps must be installed into their original locations or engine damage may occur.

Position the 3 balance shaft bearing caps and install the 6 bolts and tighten in the sequence shown.

- Tighten to 10 Nm (89 lb-in).





54. NOTICE: 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.

NOTICE: 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may 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 at the locations shown.





55. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.





56. Tighten the engine front cover fasteners in sequence in 3 stages.
Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
Stage 3: Tighten fasteners 8 through 15 to 25 Nm (18 lb-ft).













57. Install the front 4 oil pan bolts in the sequence shown, in 2 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 60 degrees.





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





59. Using the Crankshaft Vibration Damper Installer, Front Cover Seal Installer and Crankshaft Front Seal Installer, install a new crankshaft front seal.





60. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

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





61. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





62. Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).

- Stage 2: Loosen 360 degrees.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90 degrees.





63. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





64. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).





65. NOTICE: 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. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

66. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

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





67. Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





68. NOTICE: 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. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

69. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

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





70. Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





71. Position the oil level indicator and tube and install the bolt.
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.

- Tighten to 10 Nm (89 lb-in).





72. Install the oil level indicator and tube front bolt.
- Tighten to 25 Nm (18 lb-ft).





73. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.

74. Connect the CKP sensor electrical connector.





75. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

NOTE: Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.

Install the 10 ignition coils and the 10 bolts.

- Tighten to 6 Nm (53 lb-in).





76. Connect the 10 ignition coil electrical connectors.





77. Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).





78. Connect the Engine Oil Pressure (EOP) switch electrical connector.





79. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





80. Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).





81. Connect the CMP sensor electrical connector.





82. NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to install it.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.

- Tighten to 133 Nm (98 lb-ft).





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

84. Lower and support the engine assembly on wood blocks.

85. Install the Engine Lifting Bracket.





86. Using a suitable floor crane, raise the engine.

87. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).





88. Install the engine. For additional information, refer to Engine Engine - Installation in the Installation.