Cylinder Head Assembly
Cylinder Head
All cylinder heads
1. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or engine damage may occur.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.
NOTICE: The cylinder head bolts must be discarded and new bolts installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 24 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 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
3. NOTE: LH shown, RH similar.
If equipped, install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
4. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the engine may occur. They are a tighten-to-yield design and cannot be reused.
NOTICE: Clean the engine support insulator bracket mounting surface of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.
NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.
If equipped with cylinder block drain plugs, position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
LH cylinder head
5. Remove the Cylinder Head Remover/Installer from the LH cylinder head.
6. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
Install the hydraulic lash adjusters into the LH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
7. Install 10 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
8. Position 2 new gaskets, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - LH:
9. Position the exhaust manifold heat shield and install the 3 bolts.
- Tighten to 14 Nm (124 lb-in).
RH cylinder head
10. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
11. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
12. Install 10 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
13. Position 2 new gaskets, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - RH:
14. Position the exhaust manifold heat shield and install the 2 bolts.
- Tighten to 14 Nm (124 lb-in).
15. Install the heater coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).
All cylinder heads
16. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
NOTE: Camshaft shown installed to clarify camshaft roller follower position.
NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
Install only the identified camshaft roller followers onto the RH cylinder head.
17. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
NOTE: Camshaft shown installed to clarify camshaft roller follower position.
NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
Install only the identified camshaft roller followers onto the LH cylinder head.
18. Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
19. Install the 6 LH and 6 RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the 2 front camshaft bearing caps.
- Position the remaining 10 camshaft bearing caps.
- Install the 24 bolts loosely.
20. Tighten the 12 LH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
Camshaft - LH:
21. Tighten the 12 RH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
Camshaft - RH:
22. Install the balance shaft drive gear onto the LH camshaft.
23. Install both camshaft sprockets and camshaft sprocket bolts finger-tight.
24. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTICE: 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 or engine damage may occur.
Using a vise, compress the tensioner plunger.
25. Install a retaining clip on the tensioner to hold the plunger in during installation.
26. NOTE: There are 61 links in each timing chain.
If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
27. Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
28. Position the camshafts.
- Rotate the LH camshaft until the timing mark is at approximately 12 o'clock.
- Rotate the RH camshaft until the timing mark is at approximately 11 o'clock.
29. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
30. Install the crankshaft sprocket, marking sure the flange faces forward.
31. Install the lower end of the LH timing chain, aligning the timing marks.
32. 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.
33. 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 the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
34. 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.
35. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
36. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
37. Remove the retaining clips from the RH and LH timing chain tensioners.
38. Check for correct alignment of all timing marks.
39. Install the crankshaft sensor ring on the crankshaft.
40. NOTICE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
